JPWO2004080680A1 - Recycled resin manufacturing method and resin material containing recycled resin manufactured by the method - Google Patents

Abstract

The method for producing a recycled resin according to the present invention includes a dismantling and collecting step (S1) for disassembling a product having a resin molded body and collecting the resin molded body, and a removing step for removing unnecessary materials including metal parts from the resin molded body. In a method including (S2), a classification step (S3) for discriminating the material of the resin molded body, and a crushing step (S5) for crushing the resin molded body, a metal part is used as a pre-process of the crushing step (S5). Metal detection step (S4) for detecting metal and a metal separation step for separating and removing the metal remaining in the crushed material obtained in the crushing step (S5) from the crushed material as a step after the crushing step (S5) S6).

Description

  The present invention relates to a method for regenerating a resin from a resin molded body included in an electronic device, a home appliance, an interior, and the like. Furthermore, the present invention also relates to a resin material containing a regenerated resin obtained by the method.

In recent years, laws related to resource countermeasures such as the establishment of the Law on Effective Utilization of Resources have progressed, and efforts to recycle products, reuse resources, and reduce waste have become active. In particular, collection and recycling of sold products have become an important issue for manufacturers of home appliances and electronic devices.
For example, in various personal computers, printers, mobile phones, and the like, a resin material is often used as a material constituting the housing from the viewpoint of moldability and lightness. Therefore, in such a field, establishment of a resin casing recycling technique is strongly desired.
Resin casing recycling technology includes thermal recycling technology that uses the resin casing as a heat source, and cascade usage that requires relatively no reduction in physical properties of recycled resin obtained by recycling the resin casing. Recycling technology. Below, an example of the manufacturing method of the recycled resin in the recycling technique for cascade utilization is demonstrated concretely, referring FIG. First, various collected personal computers, printers, mobile phones and the like are disassembled, and the resin casings included in these are separated and collected (disassembly collection step S1 ′). Next, from the separated and collected resin casing, adhering matters such as labels and rubber feet, metal parts such as screws and springs, and unnecessary items such as dirt such as dust and dirt are removed (removal step S2 ′). Next, the material of the resin casing from which unnecessary materials have been removed is discriminated by the material display shown on the resin casing (material discriminating step S31 ′), and difficult by a flame retardant test (for example, UL94 combustion test method). The presence or absence of the addition of a flame retardant is discriminated (flame retardant test step S32 ′), and the color difference is discriminated by the inner eye (color difference discriminating step S33 ′) to perform classification (sorting step S3 ′). Next, the sorted resin casing is crushed by a crusher (crushing step S5 ′). Through these steps, recycled resin can be obtained from recovered products (such as various personal computers).
However, since the degree of deterioration of the resin contained in the resin casing varies greatly depending on the use state of the recovered product, etc., the resin material containing the recycled resin obtained by the recycling technique as shown in FIG. Thus, it has been difficult to stably obtain the same physical properties and aesthetics as the virgin resin material. Therefore, it has been difficult to use a resin material containing recycled resin as a molding material for a resin casing (for example, a resin casing constituting a recovered product) that requires high fluidity and high strength. .
Therefore, techniques that can obtain the physical properties of a resin material containing a recycled resin obtained by a recycling technique at the same level as that of a virgin resin material are disclosed in Japanese Patent Application Laid-Open Nos. 2000-198116 and 2001-30248. Is known.
However, since the techniques disclosed in Japanese Patent Application Laid-Open Nos. 2000-198116 and 2001-30248 do not select the material of the resin casing of the recovered product, there are various types of materials for the resin casing of the recovered product. When these are mixed, it becomes difficult to maintain the physical properties of the resin material including the recycled resin obtained by the recycling technique at the same level as the virgin resin material. Moreover, although metal separation processes, such as a magnetic fractionation process, are performed in multiple times, all processes are performed after the crushing process. Therefore, in the crushing process of crushing the resin casing with the crusher, if metal parts remain, the metal parts are also crushed together with the resin casing, and damage to the crusher is increased. In addition, since the amount of metal to be removed after crushing is relatively large, the amount of the resin that is removed together with the metal by adhering to the metal increases, and the resin recovery efficiency may decrease.

Therefore, the object of the present invention is to obtain the same physical properties and aesthetics as each virgin resin material by separating the materials even when various materials are mixed as the material of the resin casing of the recovered product, and An object of the present invention is to provide a method for producing a recycled resin capable of suppressing a reduction in resin recovery efficiency and reducing damage to a crusher in a crushing step.
Another object of the present invention is to provide a resin material containing a recycled resin produced by such a production method.
The method for producing a recycled resin according to the first aspect of the present invention includes dismantling a product having a resin molded body, recovering the resin molded body, and removing unnecessary materials including metal parts from the resin molded body. In a recycled resin manufacturing method including a removing step, a separating step for determining the material of the resin molded body, and a crushing step for crushing the resin molded body, a metal detector that detects a metal part as a pre-process of the crushing step And a metal separation step of separating and removing a metal component remaining in the crushed material obtained in the crushing step from the crushed material as a subsequent step of the crushing step.
According to such a method, even if the resin molded body recovered from the product is made of various materials, the resin molded body can be sorted for each material in the sorting step. Therefore, it is possible to stabilize the physical properties of the obtained recycled resin by manufacturing the recycled resin for each sorted material. In addition, by reducing the metal content in the metal detection process, metal content is mixed in the produced recycled resin, and the reduction in impact strength due to the formation of a discontinuous phase in the mixed portion is suppressed. In addition to being able to, it is possible to suppress the occurrence of poor appearance. Therefore, the physical properties of the resin material including the recycled resin produced by the method of the present invention should be maintained at the same level as that of the virgin resin material even when various types of resin molded materials are mixed. Is possible.
By providing the metal detection process before the crushing process, the possibility that metal parts and the like remain on the resin molded body to be crushed in the crushing process is further reduced. Therefore, for example, even when the resin molded body is crushed using a crusher provided with a blade portion, blade spillage of the blade portion is less likely to occur. Therefore, damage to the crusher can be reduced. In addition, since the amount of metal to be removed in the metal separation step is reduced, the amount of resin that is removed together with the metal by attaching to the metal is reduced. Therefore, it is possible to suppress a decrease in resin recovery efficiency.
Preferably, the fractionation step further includes a flame retardance test step for measuring the flame retardance of the resin molded body. By adding such a step, it becomes possible to determine whether or not the flame retardant is contained in the resin molded body. When the flame retardant is contained in the resin molded body, there is a possibility that the following problem in producing the recycled resin may occur. For example, when a phosphorus-based flame retardant is included, physical properties may deteriorate, such as the flowability of the recycled resin being increased more than necessary, and when a halogen-based flame retardant is included, the recycled resin This is undesirable from an environmental point of view. Accordingly, the presence or absence of a flame retardant is determined in the flame retardant test process, and the resin molded product containing the flame retardant is separated and removed, thereby stabilizing the physical properties of the produced recycled resin and improving the environmental resistance. be able to.
Preferably, the separation step further includes a color difference measurement step for measuring the color difference of the resin molded body. By adding such a process, it becomes possible to control the color tone of the resin after regeneration. As a result, for example, it is possible to selectively produce a recycled resin having a color tone close to white and rich in versatility, or a recycled resin having a color tone close to that of a virgin resin. Therefore, the color tone can be maintained at the same level as the virgin resin material.
Furthermore, the manufacturing method of the recycled resin may further include a crushed material separation step of separating the crushed material that has undergone the metal separation step using a sieve having a mesh size of 1 to 5 mm. By providing such a process, it becomes possible to separate and remove crushed materials having a size of 1 to 5 mm or less. By removing the crushed material having a size of 1 to 5 mm or less, the distribution range of the size of the crushed material can be narrowed. Therefore, when kneading the crushed material, kneading can be performed more uniformly. In addition, since it is possible to remove fine foreign matters that could not be removed in the removal step or the metal separation step, it is possible to produce a recycled resin with more stable physical properties.
Preferably, the detection of the metal part in the metal detection process is performed using a metal detector. As a result, the metal part can be detected more reliably than by visual observation, so that the possibility of the metal part remaining can be reduced more thoroughly.
Preferably, the metal separation step is performed by magnetic separation using magnetic force. By providing the metal separation step, it is possible to suppress the metal component from being mixed into the recycled resin. Therefore, it is possible to suppress a reduction in impact strength due to the presence of a metal component in the recycled resin and the formation of a discontinuous phase in the mixed portion. Further, by thoroughly removing the metal component, it is possible to suppress appearance defects. The magnetic separation is preferably performed using a magnet having a magnetic force with a residual magnetic flux density of the magnetic pole portion of 10,000 gauss or more.
According to the 2nd side surface of this invention, the resin material containing the reproduction | regeneration resin manufactured by the above manufacturing methods and a virgin resin is provided.
Preferably, the resin material further includes a filler and / or a flame retardant selected from the group consisting of glass fiber, carbon fiber, glass flake, glass bead, mica, talc and rubber. Thereby, physical properties such as strength and expansion coefficient of the resin material can be adjusted.

FIG. 1 is a flowchart showing a process for producing a recycled resin according to an embodiment of the present invention.
FIG. 2 is a diagram showing an example of a resin molded body that is dismantled and collected in the dismantling and collecting step.
FIG. 3 is a view showing an example of a resin molded body that has undergone the removal step.
FIG. 4 is a diagram showing the composition of the resin material produced in the examples and comparative examples of the present invention.
FIG. 5 is a table summarizing the physical properties and evaluation results of the resin materials produced in Examples and Comparative Examples of the present invention.
FIG. 6 is a flowchart of a conventional recycled resin material manufacturing method.

Hereinafter, the manufacturing method of the recycled resin which concerns on embodiment of this invention is demonstrated concretely, referring FIGS. 1-5.
FIG. 1 is a flowchart showing a series of steps from disassembly and collection of collected products (for example, various personal computers and printers) to production of recycled resin. Through these steps, a resin material of a predetermined material can be regenerated from various recovered products. FIG. 2 is a view showing an example of a resin molded body disassembled and collected from a collected product (a part of a case of a desktop personal computer).
In the dismantling and recovery step S1, the resin molded body (see FIG. 2) is recovered from the recovered product by disassembling the recovered product having the resin molded body. Examples of collected products include various personal computers and peripheral devices (printers, keyboards, displays, etc.), electronic devices such as copiers, home appliances, interiors, and the like that have resin moldings. The material of the resin molding is acrylonitrile-butadiene-styrene (ABS) resin, polycarbonate (PC) resin, polyphenyl ether (PPE) resin, polyamide (PA) resin, liquid crystal polymer (LCP) resin, polylactic acid (PLA) Examples thereof include resins such as resins, polyethylene terephthalate (PET) resins, polyphenylene sulfide (PPS) resins, polyacetal (POM) resins, polystyrene (PS) resins, and resin alloys containing these resins.
In the removal step S2, as shown in FIG. 3, the unnecessary material 1 remaining in the resin molded body (see FIG. 2) recovered in the dismantling and recovery step S1 is removed. Examples of the unnecessary material include a deposit 10 such as a label and a rubber foot, a metal part 11 such as a screw and an embedded boss, and dirt such as dust and dirt.
Specific methods for removing the unwanted material 1 include the following. In the case of the deposit 10, the deposit 10 is scraped off with a spatula or the like, or is scraped off using a grinder such as a grinder. In the case of the metal part 11, screws and springs are removed manually, and embedded bosses and the like are cut off for the surrounding resin in consideration of work efficiency. If it is dirty, blow it away with an air gun, or wipe away anything that won't fly with an air gun. If dirt (such as highly adhesive grease) that does not blow off with an air gun and cannot be wiped off with a cloth remains in the resin molded body, the resin molded body is excluded from the manufacturing process, for example, thermal recycling. It is preferable to perform (such as melting the resin and separating the dirt).
The separation step S3 includes a material discrimination step S31, a combustion test step S32, and a color difference measurement step S33, and the resin molded body is separated based on the material, the presence / absence of a flame retardant, and the color tone. In parallel with the separation, a check is also performed to determine whether or not the unnecessary material 1 remains on the resin molded body by visual inspection or the like. If the residual of the unnecessary material 1 is confirmed (NG), the resin molded body is removed. The process is fed back to step S2. On the other hand, when the residue of the unwanted material 1 is not confirmed (OK), the resin molded body is moved to the next step.
In the material discrimination step S31, the material of the resin molded body is discriminated. As this discrimination method, there is a method in which the resin molded body is applied to a material discriminator in order to discriminate the material in more detail and surely after being roughly classified for each material display stamped on the resin molded body. In the case of such a method, the resin molded body can be more reliably classified for each material (for example, ABS resin, PC resin, etc.). Therefore, even when the resin is regenerated from the resin molded body in which various materials are mixed, the physical properties of the regenerated resin can be stabilized.
In the combustion test step S32, it is determined whether or not the flame retardant is contained in the resin molded body. As a method for this determination, after confirming the presence or absence of a flame retardant from the display stamped on the resin molded body, and classifying it, a resin molded body that does not display the presence or absence of the flame retardant, and an indication that the flame retardant is not included Examples include a method in which a test piece is cut out from each of the resin molded bodies and the test piece is subjected to a flame retardancy test such as a UL94 combustion test method. When a recycled resin is produced using a resin molded body containing a flame retardant, if the flame retardant is a phosphorus flame retardant, physical properties such as a decrease in the molecular weight of the recycled resin may be caused. Moreover, when the said flame retardant is a halogenated flame retardant, when it mixes with a recycled resin, it is unpreferable from an environmental viewpoint. Therefore, it is preferable to exclude the resin molding confirmed to contain the flame retardant in the combustion test step S32 from the manufacturing process according to the present invention. However, when it is planned to add a flame retardant when producing a resin material containing a recycled resin produced by the production method according to the present invention, a resin molded article containing the flame retardant is used in the combustion test step S32. It does not have to be excluded.
In the color difference measurement step S33, the color tone of the resin molded body is determined by measuring the color difference (ΔE) of the resin molded body with respect to the color difference standard. As this discrimination method, a color difference meter is used to measure the color difference with the color tone of the resin molded product using white as a color difference standard, and then classify according to the obtained color difference (ΔE). Generally, a color tone close to white (for example, ΔE ≦ 2) has a wider range of later coloration and is more versatile. Therefore, a resin molded product in which ΔE is 2 or less with white as a color difference standard and a resin larger than 2 It is preferable to separate into a molded body and treat each separately. The color difference (ΔE) is a value that quantitatively indicates the degree of color deviation from a color (for example, white) as a color difference standard, and means that the larger the value, the larger the color deviation.
In the metal detection step S4, it is detected whether or not metal parts such as screws remain on the resin molded body. As this detection method, there is a method in which a metal detector is used to check the presence or absence of residual metal parts in the resin molded body. According to this method, since the metal part can be detected more reliably than by visual observation, the possibility of the metal part remaining can be reduced more thoroughly. When the remaining metal part is confirmed on the resin molded body (NG), the resin molded body is fed back to the removal step S2, and when the remaining metal part is not confirmed (OK), the resin molded body is the next process. Moved to.
In the crushing step S5, the resin molded body in which the metal part has not been detected in the metal detection step S4 is crushed, and a crushed material RR is obtained. Examples of the crushing method include a method of crushing using a crusher equipped with a cover mesh having a predetermined mesh size until the size of the resin molded body is equal to or smaller than the mesh size. The mesh size is preferably 8 to 10 mm. When the mesh size is less than 8 mm, fine powder (for example, 5 mm or less) increases, so that the amount of the crushed material RR that is removed in the crushed material separation step S <b> 7 described later increases, and the recycling efficiency decreases. Further, when the mesh size is larger than 10 mm, the crushed material RR is too large, so that problems such as clogging are likely to occur in the subsequent processing, and the crushed material RR may not be kneaded uniformly. is there.
In the metal separation step S6, the metal powder mixed in the crushed material RR is separated and removed. Examples of the separation / removal method include a method of separating and removing metal powder by magnetic separation using magnetic force. According to such a method, for example, even when the metal powder is mixed in the crushing step S5, the metal powder is removed in the metal separation step S6, so that the mixing of the metal powder into the recycled resin can be suppressed. Therefore, it is possible to suppress a decrease in impact strength due to the presence of metal powder in the recycled resin and the formation of a discontinuous phase in the mixed portion. Moreover, since the metal powder of the size (for example, diameter is 0.2 mm or more) which can be visually recognized can be removed thoroughly, generation | occurrence | production of an external appearance defect can be suppressed. The magnetic separation is preferably performed using a magnet having a magnetic force with a residual magnetic flux density of the magnetic pole portion of 10,000 gauss or more.
In the crushed material separation step S7, the fine crushed material RR is separated and removed. Examples of the separation and removal method include a method of separating and removing the crushed material RR having a size of 1 to 5 mm or less using a sieve having a mesh size of 1 to 5 mm. According to such a method, it is possible not only to separate and remove the foreign matter (metal powder and the like) that could not be removed in the removal step S2 and the metal separation step S6 together with the fine crushed material RR, but also the crushed recycled resin. The size distribution range can be narrowed. Accordingly, a recycled resin having more stable physical properties can be obtained, and the range of the size of the recycled resin can be narrowed, so that the recycled resin can be kneaded in a more balanced manner (the size distribution of the recycled resin). Due to the narrow range, it becomes easier to obtain a more uniform resin.
As described above, a recycled resin is produced from a resin molded body obtained by disassembling the recovered product. Further, by kneading the recycled resin and the virgin material, a resin material having physical properties equivalent to those of a resin made of only the virgin material can be obtained. Further, by adding a filler and / or a flame retardant selected from the group consisting of glass fiber, carbon fiber, glass flake, glass bead, mica, talc and rubber, a resin consisting of only a virgin material even if a regenerated resin is added It is also possible to obtain a resin material having physical properties superior to those of the material. In addition, although specific embodiment of this invention was described above, this invention is not limited to this, A various change is possible within the range which does not deviate from the thought of invention.
Next, specific examples of the present invention will be described together with comparative examples.

<Manufacture of recycled resin>
In this embodiment, in the flow shown in FIG. 1, the ABS resin is recovered from a collected product (desktop personal computer, printer, etc.) in which a resin casing made of any of ABS resin, PC resin and PS resin is mixed. A regenerated resin containing as a main component was prepared.
(Demolition collection process)
The recovered product was disassembled and the resin casing was recovered.
(Removal process)
Unnecessary substances remaining in the resin casing recovered in the dismantling and recovery step were removed. Specifically, the labels and rubber feet were scraped off with a spatula, the screws and springs were removed, and the embedded boss was cut off together with the surrounding resin. Moreover, the dust adhering to the resin case was blown off with an air gun, and the dirt not blown off was wiped off with a cloth. Resin casings that could not be wiped off were removed from the recycled resin manufacturing process.
(Material discrimination process)
First, what is displayed as “ABS resin” as a material in the material display stamped on the resin casing was extracted. Next, the resin casing without the material display and the resin casing with the display of “ABS resin” are applied to a material discriminator (trade name: PLID-3, manufactured by Toa Denpa Kogyo Co., Ltd.) to identify and check the material. Went. In addition, the resin casing in which the residue of the unnecessary thing was confirmed in the said process was fed back to the removal process.
(Combustion test process)
First, an ABS resin casing having a display indicating that a flame retardant is added to a resin casing (hereinafter referred to as an ABS resin casing) whose material is determined to be ABS resin in the material determining step is a process for producing recycled resin. Removed from. Next, a flame test was performed on the test piece cut out from the ABS resin casing without a display regarding the addition of the flame retardant by the UL 94 combustion test method to determine the flame retardancy. An ABS resin casing (hereinafter referred to as ABS resin casing (HB)) having flame retardancy of HB (UL94 standard) and an ABS resin casing (hereinafter referred to as ABS resin casing) of V-2 (UL94 standard) or higher. The ABS resin casing (≤V-2) was removed from the recycled resin production process as a flame retardant added. In addition, the resin casing in which the residue of the unnecessary thing was confirmed in the said process was fed back to the removal process.
(Color difference measurement process)
The ABS resin casing (HB) was subjected to a color difference meter (trade name: CM-2600d, manufactured by Minolta Co., Ltd.), and the color difference (ΔE) from the color tone of the ABS resin casing (HB) was measured using white as the color difference standard. Then, the ABS resin casing (HB) having a ΔE greater than 2 and the ABS resin casing (HB) having a ΔE of 2 or less were separated, and the ABS resin casing (HB) having a ΔE of 2 or less was extracted. In addition, the resin casing in which the residue of the unnecessary thing was confirmed in the said process was fed back to the removal process.
(Metal detection process)
A table metal detector (trade name: MS-3114-35S, Nisshin Denshi Kogyo Co., Ltd.) with an ABS resin casing (HB) having a ΔE of 2 or less after a separation process consisting of a material discrimination process, a combustion test process and a color difference measurement process. The ABS resin casing (HB) was examined for the presence of metal parts (screws, springs, embedded bosses, etc.). The resin casing in which the remaining metal parts were confirmed was fed back to the removal process.
(Crushing process)
The ABS resin casing, in which no metal parts remained in the metal detection process, was crushed by a crusher (screen mesh size: 8 mm).
(Metal separation process)
The ABS resin casing (hereinafter referred to as a crushed material) crushed in the crushing process is placed on the installation part of a magnet bar (two-stage, five types, manufactured by Yamasan Co., Ltd.) whose residual magnetic flux density is 12,000 gauss. The metal powder mixed in the crushed material was separated and removed by passing it through.
(Crushing material separation process)
The crushed material which passed through the metal separation step was separated and removed using a sieve having a 5 mm mesh.
As described above, a recycled resin mainly composed of ABS resin was produced as a crushed material A having a size of 5 to 8 mm.
<Residual investigation of unnecessary materials>
It was investigated whether or not unnecessary materials were mixed in the crushed material A produced as described above. First, unnecessary materials other than metal were examined visually but were not confirmed. Next, the unnecessary metal was investigated by passing the crushed material A through a lattice magnet stacked in two stages, but it was not confirmed.
<Examination of mixed materials>
First, a disc (diameter 15 mm, thickness 0.5 mm) was produced by hot pressing using the crushed material A produced as described above, and the color tone of the disc was examined. As a result, it was confirmed that the disc had roughly four color distributions: ivory, light gray, gray and dark gray. In addition, it is considered that the gray color is caused by burning or dirt at the stage of manufacturing the disc. Next, samples were taken from the portions showing the respective colors, and the components of the samples were analyzed using an FT-IR analyzer (trade name: Spectrum, manufactured by Perkin Elmer Co., Ltd.). As a result, each color sample was an ABS resin.
<Pellet productivity survey>
The pulverized material A produced as described above was examined for the extrusion state when pelletized using a twin-screw extrusion kneader (trade name: KZW-15, manufactured by Technobel Co., Ltd.) having a stirring blade. As a result, when the crushed material A was used, pellets could be produced in a very stable state without causing surging. This is considered to be due to the small variation in the size of the crushed material A (5 to 8 mm). Surging means that when the crushed material is kneaded while being heated, the crushed material is large so that the stirring blade stops due to biting, or conversely, the crushed material is small and the stirring blade is idled. This means that the rotation of the lens becomes uneven.
<Production of resin material>
Using the crushed material A produced as described above, three types of resin materials (resin material 1 to resin material 3) were produced as molding materials. The resin material 1 is obtained by mixing 20 wt% of the crushed material A and 80 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material. Resin material 2 is 20 wt% of crushed material A, 35 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material, and 35 wt% of PC resin (trade name: A1900, manufactured by Idemitsu Kosan Co., Ltd.). , Phosphorus flame retardant (trade name: ADK STAB, manufactured by Asahi Denka Kogyo Co., Ltd.) is mixed at 10 wt%. Resin material 3 is 20 wt% of crushed material A, 30 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Co., Ltd.) as a virgin material, and 30 wt% of PC resin (trade name: A1900, manufactured by Idemitsu Kosan Co., Ltd.). 10 wt% of a phosphorus-based flame retardant (trade name: ADK STAB, manufactured by Asahi Denka Kogyo Co., Ltd.) and 10 wt% of glass fiber (trade name: CS 03 MA FT737, manufactured by Asahi Fiber Glass Co., Ltd.). Each material composition is shown in FIG. Next, resin materials 1 to 3 were melt-kneaded at about 230 ° C. using a twin-screw extrusion kneader (trade name: KZW-15, manufactured by Technobel Co., Ltd.). Furthermore, the melt-kneaded resin materials 1 to 3 were each pelletized using a strand cut pelletizer (trade name: SCP-102, manufactured by Technobel Co., Ltd.).
<Production of resin molding>
From the pellets of the resin materials 1 to 3 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), molded body samples 1 to 3 (respectively lengths). 126 mm, width 12.8 mm, thickness 3.2 mm).
<Measurement of bending strength>
The bending strength was measured about the molded object samples 1-3 produced as mentioned above. Specifically, using a universal testing machine (trade name: Instron 5581, manufactured by Instron Japan), a three-point bending test was performed on each of the molded body samples 1 to 3 in accordance with JIS K 7055. The bending strength of the molded body sample was measured by setting the distance (span) between the two support points to 51.2 mm and applying a pressing force to the approximate center between the two support points. As a result, the molded body sample 1 830kgf / cm ^2, the molded body sample 2 981kgf / cm ^2, the molded body sample 3 showed a bending strength of 1020kgf / cm ^2. These results are shown in FIG. The bending strength of the resin material is desirably 800 kgf / cm ² or more.
<Measurement of flexural modulus>
The bending elastic modulus was measured about the molded object samples 1-3 produced as mentioned above. Specifically, a bending elastic modulus test was performed on each of the molded body samples 1 to 3 in accordance with JIS K 7055 using a universal testing machine (trade name: Instron 5581, manufactured by Instron Japan). The bending elastic modulus of the molded body sample was measured by setting the distance (span) between the two support points to 51.2 mm and applying a pressing force to the approximate center between the two support points. As a result, the molded body sample 1 29600kgf / cm ^2, the molded body sample 2 34200kgf / cm ^2, the molded body sample 3 exhibited a flexural modulus of 48000kgf / cm ^2. These results are shown in FIG. In addition, as a resin material, a bending elastic modulus is desired to be 25000 kgf / cm ² or more.
<Izod impact test>
Using pellets of resin materials 1 to 3 obtained as described above, an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.) is used for an Izod impact test in accordance with JIS K 7110. Izod impact test specimens 1 to 3 (each 126 mm long, 12.8 mm wide, 3.2 mm thick, and 2.54 mm deep notch depth in the thickness direction) were molded to form Izod impacts. The test specimens 1 to 3 were examined for impact resistance. Specifically, an Izod impact test was performed in accordance with JIS K 7110 using an Izod impact tester (trade name: Impact Tester, manufactured by Toyo Seiki Seisakusho Co., Ltd.). The Izod impact value in the flatwise impact was 11 kgfcm / cm for the Izod impact test specimen 1, 18 kgfcm / cm for the Izod impact test specimen 2, and 35 kgfcm / cm for the Izod impact test specimen 3 ′. These results are shown in FIG. It should be noted that the Izod impact strength of the resin material is desirably 8 kgfcm / cm or more.
<Evaluation of fluidity>
Resin material obtained as described above using a bar flow mold that defines a cavity (full length of flow path: 1650 mm, width of flow path: 10 mm, thickness of flow path: 1 mm, mold temperature: 120 ° C.) The flow length was measured when the molten resin materials 1 to 3 in which the pellets 1 to 3 were melted at 220 ° C. were injection molded at an injection pressure of 1600 kgf / cm ² . As a result, the molten resin material 1 showed a flow length of 160 mm, the molten resin material 2 of 161 mm, and the molten resin material 3 of 161 mm. These results are shown in FIG. Note that the flow length of the resin material is desirably 150 mm or more.
<Evaluation of flame retardancy>
From the pellets of the resin materials 1 to 3 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), test pieces for combustion test 1 to 3 (125 mm × 13 mm × 1 mm) and a combustion test was performed. Specifically, according to a method based on the UL94 vertical combustion test method, a burn test is performed by bringing a burner flame of about 2.5 cm into contact with each test piece in a UL combustion test chamber (trade name: HVUL, manufactured by Toyo Seiki). And flame retardancy was evaluated. These results are shown in FIG.
<Measurement of color difference>
The molded product samples 1 to 3 produced as described above are subjected to a color difference meter (trade name: CM-2600d, manufactured by Minolta Co., Ltd.), and the color difference (ΔE) from the color tone of the molded product samples 1 to 3 using white as the color difference standard. Was measured. As a result, the molded product sample 1 showed a color difference of 1.2, the molded product sample 2 showed a color difference of 1.8, and the molded product sample 3 showed a color difference of 1.8. These results are shown in FIG. In addition, as a resin material, it is desirable that a color difference is 2 or less.
<Appearance evaluation>
By observing the appearances of the molded body samples 1 to 3 produced as described above, the quality of each molded body sample was evaluated based on the degree of occurrence of sink marks and flashes (good: ◯, no: x). . These results are shown in FIG.
<Evaluation of paintability>
The quality (good: ◯, no: x) of the paintability of each molded body sample was evaluated from the coating state when the molded body samples 1 to 3 produced as described above were coated. These results are shown in FIG.
<Investigation of foreign matter residue>
Using resin materials 1 to 3, sample disks 1 to 3 (diameter 15 mm, thickness 0.5 mm) are prepared by hot pressing, and a foreign substance (black) can be visually recognized by observing the appearance of the sample disks 1 to 3 The number of those having a diameter of 0.2 mm or more and one having a diameter of 0.1 mm or more and less than 0.2 mm was counted. In the sample disc 1, 0 foreign matter having a diameter of 0.2 mm or more was detected per disc, and 1 foreign matter having a diameter of 0.1 mm or more and less than 0.2 mm was detected per disc. In the sample disc 2, 0 foreign matter having a diameter of 0.2 mm or more was detected per disc, and 2 foreign matters having a diameter of 0.1 mm or more and less than 0.2 mm were detected per disc. In the sample disk 3, 0 foreign matter having a diameter of 0.2 mm or more was detected per disc and 2 foreign matters having a diameter of 0.1 mm or more and less than 0.2 mm were detected per disc. These results are shown in FIG. In evaluating foreign matter, foreign matter having a diameter of 0.2 mm or more (dot-like dirt) is not included, and no more than two foreign matters have a diameter of 0.1 mm or more and less than 0.2 mm. It is desirable that
[Comparative example]
<Production of recycled resin>
In this comparative example, in the flow shown in FIG. 6, the collection including a resin case made of a resin selected from the group consisting of acrylonitrile-butadiene-styrene (ABS) resin, polycarbonate resin, and polystyrene resin is mixed. A recycled resin containing ABS resin as a main component was produced from a product (desktop personal computer, printer, etc.).
(Demolition collection process S1 ')
The recovered product was disassembled and the resin casing was recovered.
(Removal step S2 ′)
Unnecessary substances remaining in the resin casing recovered in the dismantling and recovery step S1 ′ were removed. Specifically, the labels and rubber feet were scraped off with a spatula, the screws and springs were removed, and the embedded boss was cut off together with the surrounding resin. Moreover, the dust adhering to the resin case was blown off with an air gun, and the dirt not blown off was wiped off with a cloth. Resin casings that could not be wiped off were removed from the recycled resin manufacturing process.
(S31 ′ of material discrimination step S3 ′)
In the material display engraved on the resin casing, the material indicated as “ABS resin” was extracted.
(S32 ′ of combustion test step S3 ′)
The flame retardancy was determined in the same manner as in the example. Then, the resin is separated into an ABS resin casing (HB) and an ABS resin casing (≦ V-2), and the ABS resin casing (≦ V-2) is manufactured as a flame retardant added. Removed from the process.
(S33 ′ of color difference measurement step S3 ′)
An ABS resin casing (HB) that was judged to be white based on the naked eye was extracted.
(Crushing step S5 ′)
The ABS resin casing that had undergone the above-described color difference measurement step was crushed by a crusher (screen mesh size: 20 mm).
As described above, a recycled resin containing ABS resin as a main component was produced as a crushed material B having a size of 20 mm or less.
<Residual investigation of unnecessary materials>
It was investigated whether or not unnecessary materials remained in the crushed material B produced as described above. First, unnecessary materials other than metal were examined visually. As a result, it was confirmed that deposits such as labels remained. Next, the unnecessary metal was investigated by passing the crushed material through a lattice magnet stacked in two stages. As a result, it was confirmed that the metal, which is considered to be derived from the embedded boss, remained.
<Examination of mixed materials>
First, a disc (diameter 15 mm, thickness 0.5 mm) was produced by hot pressing using the crushed material B produced as described above, and the color tone of the disc was examined. As a result, it was confirmed that the disc had roughly four color distributions: ivory, light gray, gray and dark gray. In addition, it is considered that the gray color is caused by burning or dirt at the stage of manufacturing the disc. Next, samples were taken from the portions showing the respective colors, and the components of the samples were analyzed using an FT-IR analyzer (trade name: Spectrum, manufactured by Perkin Elmer Co., Ltd.). As a result, each color sample was ABS resin, but high impact polystyrene resin was also detected from the light gray portion and dark gray portion samples. This is considered to have occurred because other materials are not sufficiently prevented from being mixed, such as when there is a material in which only the main component is described in the material display in the material discrimination step.
<Pellet productivity survey>
The extrusion state at the time of pelletizing the crushed material B produced as described above using a twin-screw extrusion kneader (trade name: KZW-15, manufactured by Technobel Co., Ltd.) having a stirring blade was examined. As a result, when the crushed material B was used, clogging occurred in the twin-screw extrusion kneader, making it difficult to produce uniform pellets. This is considered to be due to the fact that the size variation of the crushed material is large (20 mm or less) and the maximum value (20 mm) of the size of the crushed material B is large.
<Production of resin material>
Using the crushed material B produced as described above, a resin material 4 as a molding material was produced, and a resin material 5 made of only a virgin material was also produced. The resin material 4 is obtained by mixing 20 wt% of the crushed material B and 80 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material. Moreover, the resin material 5 is 100 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material. The composition of each material is shown in FIG. Next, the resin materials 4 to 5 were each pelletized in the same manner as in the example.
<Production of resin molding>
From the pellets of the resin materials 4 to 5 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), molded body samples 4 to 5 (respectively lengths). 126 mm, width 12.8 mm, thickness 3.2 mm).
<Measurement of bending strength>
About the molded object samples 4-5 produced as mentioned above, bending strength was measured like the Example. As a result, the molded body sample 4 exhibited a bending strength of 750 kgf / cm ² , and the molded body 5 exhibited a bending strength of 840 kgf / cm ² . These results are shown in FIG.
<Measurement of flexural modulus>
About the molded object samples 4-5 produced as mentioned above, the bending elastic modulus was measured like the Example. As a result, the molded product sample 4 showed a flexural modulus of 24000 kgf / cm ² , and the molded product sample 5 showed a flexural modulus of 30000 kgf / cm ² . These results are shown in FIG.
<Izod impact test>
From the pellets of the resin materials 4 to 5 obtained as described above, Izod impact test specimens 4 to 5 (length 126 mm, width 12.8 mm, thickness 3.2 mm, respectively) in the same manner as in the examples. A notch having a depth in the thickness direction of 2.54 mm) was molded and the impact resistance of the Izod impact test specimens 4 to 5 was examined. The Izod impact value in flatwise impact was 6 kgfcm / cm for the Izod impact test specimen 4 and 11 kgfcm / cm for the Izod impact test specimen 5. These results are shown in FIG.
<Evaluation of fluidity>
In the same manner as in the example, the flow length was measured when molten resin materials 1 to 3 in which pellets of resin materials 1 to 3 were melted at 220 ° C. were injection molded at an injection pressure of 1600 kgf / cm ² . As a result, the molten resin material 4 showed a flow length of 142 mm, and the molten resin material 5 showed a flow length of 153 mm. These results are shown in FIG.
<Evaluation of flame retardancy>
From the pellets of the resin materials 4 to 5 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), test pieces for combustion test 4 to 5 (125 mm × 13 mm × 1 mm), a combustion test was performed, and the flame retardancy was evaluated. These results are shown in FIG.
<Measurement of color difference>
The molded product samples 4 to 5 produced as described above are subjected to a color difference meter (trade name: CM-2600d, manufactured by Minolta Co., Ltd.), and the color difference (ΔE) from the color tone of the molded product samples 4 to 5 using white as the color difference standard. Was measured. As a result, the molded product sample 4 showed a color difference of 2.4, and the molded product sample 5 showed a color difference of 1.1. These results are shown in FIG.
<Appearance evaluation>
By observing the appearances of the molded body samples 4 to 5 produced as described above, the quality of each molded body sample was evaluated from the degree of occurrence of sink marks, flashes, and the like (good: ◯, no: x). . These results are shown in FIG.
<Evaluation of paintability>
The quality (good: ◯, no: x) of the paintability of each molded body sample was evaluated from the coating state when the molded body samples 4 to 5 produced as described above were coated. These results are shown in FIG.
<Investigation of foreign matter residue>
Using resin materials 1 to 3, sample disks 4 to 5 (diameter 15 mm, thickness 0.5 mm) are prepared by hot pressing, and foreign matters (black color) that can be visually recognized by observing the appearance of the sample disks 4 to 5 The number of those having a diameter of 0.2 mm or more and one having a diameter of 0.1 mm or more and less than 0.2 mm was counted. As a result, in the sample disk 4, five foreign matters having a diameter of 0.2 mm or more were detected per disc, and 23 foreign matters having a diameter of 0.1 mm or more and less than 0.2 mm were detected per disc. The sample disk 5 detected 0 foreign matter having a diameter of 0.2 mm or more per disk and 0.5 foreign matter having a diameter of 0.1 mm or more and less than 0.2 mm per disk. These results are shown in FIG.
<Evaluation>
As shown in FIG. 5, when the physical properties of the resin material 1 and the physical properties of the resin material 4 are compared, the resin material 4 including the recycled resin (crushed material B) obtained by the conventional manufacturing method has a physical property of resin. Although the standard desired as a material was not reached, the resin material 1 containing the recycled resin (crushed material A) obtained by the production method according to the present invention had a result that the physical properties satisfy all the predetermined standards. Further, compared with the physical properties of the resin material 5 made only of the virgin material, the physical properties of the resin material 1 were almost the same, and the physical properties of the resin materials 2 and 3 were both higher than the resin material 5.

[Document Name] Description [Claims]
1. A dismantling and collecting step of disassembling a product having a resin molded body and recovering the resin molded body, a removing step of removing unnecessary materials including metal parts from the resin molded body, In a method for producing a recycled resin, comprising a separation step of discriminating a material and a crushing step of crushing the resin molded body,
As a pre-process of the crushing process, a metal detection process for detecting the metal component, and as a subsequent process of the crushing process, the metal remaining in the crushing material obtained in the crushing process is separated and removed from the crushing material. A method for producing a recycled resin, comprising: a metal separation step.
2. The method for producing a recycled resin according to claim 1, wherein the fractionation step further includes a combustion test step for measuring flame retardancy of the resin molded body.
3. The method for producing a recycled resin according to claim 1, wherein the fractionation step further includes a color difference measurement step of measuring a color difference of the resin molded body.
4. The method for producing a recycled resin according to claim 1, further comprising a crushing material separation step of separating the crushing material that has undergone the metal separation step using a sieve having a mesh size of 1 to 5 mm. .
5. A resin material comprising a recycled resin produced by the method according to any one of claims 1 to 4 and a virgin resin.
DETAILED DESCRIPTION OF THE INVENTION
[0001]
【Technical field】
The present invention relates to a method for regenerating a resin from a resin molded body included in an electronic device, a home appliance, an interior, and the like. Furthermore, the present invention also relates to a resin material containing a regenerated resin obtained by the method.
[0002]
[Background]
In recent years, laws related to resource countermeasures such as the establishment of the Law on Effective Utilization of Resources have progressed, and efforts to recycle products, reuse resources, and reduce waste have become active. In particular, collection and recycling of sold products have become an important issue for manufacturers of home appliances and electronic devices.
[0003]
For example, in various personal computers, printers, mobile phones, and the like, a resin material is often used as a material constituting the housing from the viewpoint of moldability and lightness. Therefore, in such a field, establishment of a resin casing recycling technique is strongly desired.
[0004]
Resin casing recycling technology includes thermal recycling technology that uses the resin casing as a heat source, and cascade usage that requires relatively no reduction in physical properties of recycled resin obtained by recycling the resin casing. Recycling technology. Below, an example of the manufacturing method of the recycled resin in the recycling technique for cascade utilization is demonstrated concretely, referring FIG. First, various collected personal computers, printers, mobile phones and the like are disassembled, and the resin casings included in these are separated and collected (disassembly collection step S1 ′). Next, from the separated and collected resin casing, adhering matters such as labels and rubber feet, metal parts such as screws and springs, and unnecessary items such as dirt such as dust and dirt are removed (removal step S2 ′). Next, the material of the resin casing from which unnecessary materials have been removed is discriminated by the material display shown on the resin casing (material discriminating step S31 ′), and difficult by a flame retardant test (for example, UL94 combustion test method). The presence or absence of the addition of the fuel is discriminated ( combustion test step S32 ′), and the color difference is identified by the naked eye (color difference identifying step S33 ′) to perform classification (sorting step S3 ′). Next, the sorted resin casing is crushed by a crusher (crushing step S5 ′). Through these steps, recycled resin can be obtained from recovered products (such as various personal computers).
[0005]
However, since the degree of deterioration of the resin contained in the resin casing varies greatly depending on the use state of the recovered product, etc., the resin material containing the recycled resin obtained by the recycling technique as shown in FIG. Thus, it has been difficult to stably obtain the same physical properties and aesthetics as the virgin resin material. Therefore, it has been difficult to use a resin material containing recycled resin as a molding material for a resin casing (for example, a resin casing constituting a recovered product) that requires high fluidity and high strength. .
[0006]
Therefore, techniques that can obtain the physical properties of a resin material containing a recycled resin obtained by a recycling technique at the same level as that of a virgin resin material are disclosed in Japanese Patent Application Laid-Open Nos. 2000-198116 and 2001-30248. Is known.
[0007]
However, since the techniques disclosed in Japanese Patent Application Laid-Open Nos. 2000-198116 and 2001-30248 do not select the material of the resin casing of the recovered product, there are various types of materials for the resin casing of the recovered product. When these are mixed, it becomes difficult to maintain the physical properties of the resin material including the recycled resin obtained by the recycling technique at the same level as the virgin resin material. Moreover, although metal separation processes, such as a magnetic fractionation process, are performed in multiple times, all processes are performed after the crushing process. Therefore, in the crushing process of crushing the resin casing with the crusher, if metal parts remain, the metal parts are also crushed together with the resin casing, and damage to the crusher is increased. In addition, since the amount of metal to be removed after crushing is relatively large, the amount of the resin that is removed together with the metal by adhering to the metal increases, and the resin recovery efficiency may decrease.
[0008]
DISCLOSURE OF THE INVENTION
Therefore, the object of the present invention is to obtain the same physical properties and aesthetics as each virgin resin material by separating the materials even when various materials are mixed as the material of the resin casing of the recovered product, and An object of the present invention is to provide a method for producing a recycled resin capable of suppressing a reduction in resin recovery efficiency and reducing damage to a crusher in a crushing step.
[0009]
Another object of the present invention is to provide a resin material containing a recycled resin produced by such a production method.
[0010]
The method for producing a recycled resin according to the first aspect of the present invention includes dismantling a product having a resin molded body, recovering the resin molded body, and removing unnecessary materials including metal parts from the resin molded body. In a recycled resin manufacturing method including a removing step, a separating step for determining the material of the resin molded body, and a crushing step for crushing the resin molded body, a metal detector that detects a metal part as a pre-process of the crushing step And a metal separation step of separating and removing a metal component remaining in the crushed material obtained in the crushing step from the crushed material as a subsequent step of the crushing step.
[0011]
According to such a method, even if the resin molded body recovered from the product is made of various materials, the resin molded body can be sorted for each material in the sorting step. Therefore, it is possible to stabilize the physical properties of the obtained recycled resin by manufacturing the recycled resin for each sorted material. In addition, by reducing the metal content in the metal detection process, metal content is mixed in the produced recycled resin, and the reduction in impact strength due to the formation of a discontinuous phase in the mixed portion is suppressed. In addition to being able to, it is possible to suppress the occurrence of poor appearance. Therefore, the physical properties of the resin material including the recycled resin produced by the method of the present invention should be maintained at the same level as that of the virgin resin material even when various types of resin molded materials are mixed. Is possible.
[0012]
By providing the metal detection process before the crushing process, the possibility that metal parts and the like remain on the resin molded body to be crushed in the crushing process is further reduced. Therefore, for example, even when the resin molded body is crushed using a crusher provided with a blade portion, blade spillage of the blade portion is less likely to occur. Therefore, damage to the crusher can be reduced. In addition, since the amount of metal to be removed in the metal separation step is reduced, the amount of resin that is removed together with the metal by attaching to the metal is reduced. Therefore, it is possible to suppress a decrease in resin recovery efficiency.
[0013]
Preferably, the separation step further includes a combustion test step for measuring the flame retardancy of the resin molded body. By adding such a step, it becomes possible to determine whether or not the flame retardant is contained in the resin molded body. When the flame retardant is contained in the resin molded body, the following problems may occur when the recycled resin is manufactured. For example, when a phosphorus-based flame retardant is included, physical properties may deteriorate, such as the flowability of the recycled resin being increased more than necessary, and when a halogen-based flame retardant is included, the recycled resin This is undesirable from an environmental point of view. Therefore, in the combustion test process, the presence or absence of a flame retardant is determined, and the resin molded product containing the flame retardant is separated and removed, thereby stabilizing the physical properties of the produced recycled resin and improving the environmental resistance. Can do.
[0014]
Preferably, the separation step further includes a color difference measurement step for measuring the color difference of the resin molded body. By adding such a process, it becomes possible to control the color tone of the resin after regeneration. As a result, for example, it is possible to selectively produce a recycled resin having a color tone close to white and rich in versatility, or a recycled resin having a color tone close to that of a virgin resin. Therefore, the color tone can be maintained at the same level as the virgin resin material.
[0015]
Furthermore, the manufacturing method of the recycled resin may further include a crushed material separation step of separating the crushed material that has undergone the metal separation step using a sieve having a mesh size of 1 to 5 mm. By providing such a process, it becomes possible to separate and remove crushed materials having a size of 1 to 5 mm or less. By removing the crushed material having a size of 1 to 5 mm or less, the distribution range of the size of the crushed material can be narrowed. Therefore, when kneading the crushed material, kneading can be performed more uniformly. In addition, since it is possible to remove fine foreign matters that could not be removed in the removal step or the metal separation step, it is possible to produce a recycled resin with more stable physical properties.
[0016]
Preferably, the detection of the metal part in the metal detection process is performed using a metal detector. As a result, the metal part can be detected more reliably than by visual observation, so that the possibility of the metal part remaining can be reduced more thoroughly.
[0017]
Preferably, the metal separation step is performed by magnetic separation using magnetic force. By providing the metal separation step, it is possible to suppress the metal component from being mixed into the recycled resin. Therefore, it is possible to suppress a reduction in impact strength due to the presence of a metal component in the recycled resin and the formation of a discontinuous phase in the mixed portion. Further, by thoroughly removing the metal component, it is possible to suppress appearance defects. The magnetic separation is preferably performed using a magnet having a magnetic force with a residual magnetic flux density of the magnetic pole portion of 10,000 gauss or more.
[0018]
According to the 2nd side surface of this invention, the resin material containing the reproduction | regeneration resin manufactured by the above manufacturing methods and a virgin resin is provided.
[0019]
Preferably, the resin material further includes a filler and / or a flame retardant selected from the group consisting of glass fiber, carbon fiber, glass flake, glass bead, mica, talc and rubber. Thereby, physical properties such as strength and expansion coefficient of the resin material can be adjusted.
[0020]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the manufacturing method of the recycled resin which concerns on embodiment of this invention is demonstrated concretely, referring FIGS. 1-5.
[0021]
FIG. 1 is a flowchart showing a series of steps from disassembly and collection of collected products (for example, various personal computers and printers) to production of recycled resin. Through these steps, a resin material of a predetermined material can be regenerated from various recovered products. FIG. 2 is a view showing an example of a resin molded body disassembled and collected from a collected product (a part of a case of a desktop personal computer).
[0022]
In the dismantling and recovery step S1, the resin molded body (see FIG. 2) is recovered from the recovered product by disassembling the recovered product having the resin molded body. Examples of collected products include various personal computers and peripheral devices (printers, keyboards, displays, etc.), electronic devices such as copiers, home appliances, interiors, and the like that have resin moldings. The material of the resin molding is acrylonitrile-butadiene-styrene (ABS) resin, polycarbonate (PC) resin, polyphenyl ether (PPE) resin, polyamide (PA) resin, liquid crystal polymer (LCP) resin, polylactic acid (PLA) Examples thereof include resins such as resins, polyethylene terephthalate (PET) resins, polyphenylene sulfide (PPS) resins, polyacetal (POM) resins, polystyrene (PS) resins, and resin alloys containing these resins.
[0023]
In the removal step S2, as shown in FIG. 3, the unnecessary material 1 remaining in the resin molded body (see FIG. 2) recovered in the dismantling and recovery step S1 is removed. Examples of the unnecessary material include a deposit 10 such as a label and a rubber foot, a metal part 11 such as a screw and an embedded boss, and dirt such as dust and dirt.
[0024]
Specific methods for removing the unwanted material 1 include the following. In the case of the deposit 10, the deposit 10 is scraped off with a spatula or the like, or is scraped off using a grinder such as a grinder. In the case of the metal part 11, screws and springs are removed manually, and embedded bosses and the like are cut off for the surrounding resin in consideration of work efficiency. If it is dirty, blow it away with an air gun, or wipe away anything that won't fly with an air gun. If dirt (such as highly adhesive grease) that does not blow off with an air gun and cannot be wiped off with a cloth remains in the resin molded body, the resin molded body is excluded from the manufacturing process, for example, thermal recycling. It is preferable to perform (such as melting the resin and separating the dirt).
[0025]
The separation step S3 includes a material discrimination step S31, a combustion test step S32, and a color difference measurement step S33, and the resin molded body is separated based on the material, the presence / absence of a flame retardant, and the color tone. In parallel with the separation, a check is also performed to determine whether or not the unnecessary material 1 remains on the resin molded body by visual inspection or the like. If the residual of the unnecessary material 1 is confirmed (NG), the resin molded body is removed. The process is fed back to step S2. On the other hand, when the residue of the unwanted material 1 is not confirmed (OK), the resin molded body is moved to the next step.
[0026]
In the material discrimination step S31, the material of the resin molded body is discriminated. As this discrimination method, there is a method in which the resin molded body is applied to a material discriminator in order to discriminate the material in more detail and surely after being roughly classified for each material display stamped on the resin molded body. In the case of such a method, the resin molded body can be more reliably classified for each material (for example, ABS resin, PC resin, etc.). Therefore, even when the resin is regenerated from the resin molded body in which various materials are mixed, the physical properties of the regenerated resin can be stabilized.
[0027]
In the combustion test step S32, it is determined whether or not the flame retardant is contained in the resin molded body. As a method for this determination, after confirming the presence or absence of a flame retardant from the display stamped on the resin molded body, and classifying it, a resin molded body that does not display the presence or absence of the flame retardant, and an indication that the flame retardant is not included Examples include a method in which a test piece is cut out from each of the resin molded bodies and the test piece is subjected to a flame retardancy test such as a UL94 combustion test method. When a recycled resin is produced using a resin molded body containing a flame retardant, if the flame retardant is a phosphorus flame retardant, physical properties such as a decrease in the molecular weight of the recycled resin may be caused. Moreover, when the said flame retardant is a halogenated flame retardant, when it mixes with a recycled resin, it is unpreferable from an environmental viewpoint. Therefore, it is preferable to exclude the resin molding confirmed to contain the flame retardant in the combustion test step S32 from the manufacturing process according to the present invention. However, when it is planned to add a flame retardant when producing a resin material containing a recycled resin produced by the production method according to the present invention, a resin molded article containing the flame retardant is used in the combustion test step S32. It does not have to be excluded.
[0028]
In the color difference measurement step S33, the color tone of the resin molded body is determined by measuring the color difference (ΔE) of the resin molded body with respect to the color difference standard. As this discrimination method, a color difference meter is used to measure the color difference with the color tone of the resin molded product using white as a color difference standard, and then classify according to the obtained color difference (ΔE). Generally, a color tone close to white (for example, ΔE ≦ 2) has a wider range of later coloration and is more versatile. Therefore, a resin molded product in which ΔE is 2 or less with white as a color difference standard and a resin larger than 2 It is preferable to separate into a molded body and treat each separately. The color difference (ΔE) is a value that quantitatively indicates the degree of color deviation from a color (for example, white) as a color difference standard, and means that the larger the value, the larger the color deviation.
[0029]
In the metal detection step S4, it is detected whether or not metal parts such as screws remain on the resin molded body. As this detection method, there is a method in which a metal detector is used to check the presence or absence of residual metal parts in the resin molded body. According to this method, since the metal part can be detected more reliably than by visual observation, the possibility of the metal part remaining can be reduced more thoroughly. In addition, when the residue of the metal part is confirmed in the resin molded body (NG), the resin molded body is fed back to the removal step S2, and when the residue of the metal part is not confirmed (OK), the resin molded body is the next process. Moved to.
[0030]
In the crushing step S5, the resin molded body in which the metal part has not been detected in the metal detection step S4 is crushed, and a crushed material RR is obtained. Examples of the crushing method include a method of crushing using a crusher equipped with a cover mesh having a predetermined mesh size until the size of the resin molded body is equal to or smaller than the mesh size. The mesh size is preferably 8 to 10 mm. When the mesh size is less than 8 mm, fine powder (for example, 5 mm or less) increases, so that the amount of the crushed material RR that is removed in the crushed material separation step S <b> 7 described later increases, and the recycling efficiency decreases. Further, when the mesh size is larger than 10 mm, the crushed material RR is too large, so that problems such as clogging are likely to occur in the subsequent processing, and the crushed material RR may not be kneaded uniformly. is there.
[0031]
In the metal separation step S6, the metal powder mixed in the crushed material RR is separated and removed. Examples of the separation / removal method include a method of separating and removing metal powder by magnetic separation using magnetic force. According to such a method, for example, even when the metal powder is mixed in the crushing step S5, the metal powder is removed in the metal separation step S6, so that the mixing of the metal powder into the recycled resin can be suppressed. Therefore, it is possible to suppress a decrease in impact strength due to the presence of metal powder in the recycled resin and the formation of a discontinuous phase in the mixed portion. Moreover, since the metal powder of the size (for example, diameter is 0.2 mm or more) which can be visually recognized can be removed thoroughly, generation | occurrence | production of an external appearance defect can be suppressed. The magnetic separation is preferably performed using a magnet having a magnetic force with a residual magnetic flux density of the magnetic pole portion of 10,000 gauss or more.
[0032]
In the crushed material separation step S7, the fine crushed material RR is separated and removed. Examples of the separation and removal method include a method of separating and removing the crushed material RR having a size of 1 to 5 mm or less using a sieve having a mesh size of 1 to 5 mm. According to such a method, it is possible not only to separate and remove the foreign matter (metal powder and the like) that could not be removed in the removal step S2 and the metal separation step S6 together with the fine crushed material RR, but also the crushed recycled resin. The size distribution range can be narrowed. Accordingly, a recycled resin having more stable physical properties can be obtained and the distribution range of the size of the recycled resin can be narrowed, so that the recycled resin can be kneaded in a more balanced manner (the distribution of the size of the recycled resin). Due to the narrow range, it becomes easier to obtain a more uniform resin.
[0033]
As described above, a recycled resin is produced from a resin molded body obtained by disassembling the recovered product. Further, by kneading the recycled resin and the virgin material, a resin material having physical properties equivalent to those of a resin made of only the virgin material can be obtained. Further, by adding a filler and / or a flame retardant selected from the group consisting of glass fiber, carbon fiber, glass flake, glass bead, mica, talc and rubber, a resin consisting of only a virgin material even if a regenerated resin is added It is also possible to obtain a resin material having physical properties superior to those of the material. In addition, although specific embodiment of this invention was described above, this invention is not limited to this, A various change is possible within the range which does not deviate from the thought of invention.
[0034]
Next, specific examples of the present invention will be described together with comparative examples.
[0035]
[Example]
<Manufacture of recycled resin>
In this embodiment, in the flow shown in FIG. 1, the ABS resin is recovered from a collected product (desktop personal computer, printer, etc.) in which a resin casing made of any of ABS resin, PC resin and PS resin is mixed. A regenerated resin containing as a main component was prepared.
[0036]
(Demolition collection process)
The recovered product was disassembled and the resin casing was recovered.
[0037]
(Removal process)
Unnecessary substances remaining in the resin casing recovered in the dismantling and recovery step were removed. Specifically, the labels and rubber feet were scraped off with a spatula, the screws and springs were removed, and the embedded boss was cut off together with the surrounding resin. Moreover, the dust adhering to the resin case was blown off with an air gun, and the dirt not blown off was wiped off with a cloth. Resin casings that could not be wiped off were removed from the recycled resin manufacturing process.
[0038]
(Material discrimination process)
First, what is displayed as “ABS resin” as a material in the material display stamped on the resin casing was extracted. Next, the resin casing without the material display and the resin casing with the display of “ABS resin” are applied to a material discriminator (trade name: PLID-3, manufactured by Toa Denpa Kogyo Co., Ltd.) to identify and check the material. Went. In addition, the resin casing in which the residue of the unnecessary thing was confirmed in the said process was fed back to the removal process.
[0039]
(Combustion test process)
First, an ABS resin casing having a display indicating that a flame retardant is added to a resin casing (hereinafter referred to as an ABS resin casing) whose material is determined to be ABS resin in the material determining step is a process for producing recycled resin. Removed from. Next, a flame test was performed on the test piece cut out from the ABS resin casing without a display regarding the addition of the flame retardant by the UL 94 combustion test method to determine the flame retardancy. An ABS resin casing (hereinafter referred to as ABS resin casing (HB)) having flame retardancy of HB (UL94 standard) and an ABS resin casing (hereinafter referred to as ABS resin casing) of V-2 (UL94 standard) or higher. body (V -2) and referred) and fractionated into the ABS resin casing (V -2) was removed from the manufacturing process of the recycled resin as being added flame retardants. In addition, the resin casing in which the residue of the unnecessary thing was confirmed in the said process was fed back to the removal process.
[0040]
(Color difference measurement process)
The ABS resin casing (HB) was subjected to a color difference meter (trade name: CM-2600d, manufactured by Minolta Co., Ltd.), and the color difference (ΔE) from the color tone of the ABS resin casing (HB) was measured using white as the color difference standard. Then, the ABS resin casing (HB) having a ΔE greater than 2 and the ABS resin casing (HB) having a ΔE of 2 or less were separated, and the ABS resin casing (HB) having a ΔE of 2 or less was extracted. In addition, the resin casing in which the residue of the unnecessary thing was confirmed in the said process was fed back to the removal process.
[0041]
(Metal detection process)
A table metal detector (trade name: MS-3114-35S, Nisshin Denshi Kogyo Co., Ltd.) with an ABS resin casing (HB) having a ΔE of 2 or less after a separation process consisting of a material discrimination process, a combustion test process and a color difference measurement process. The ABS resin casing (HB) was examined for the presence of metal parts (screws, springs, embedded bosses, etc.). The resin casing in which the remaining metal parts were confirmed was fed back to the removal process.
[0042]
(Crushing process)
The ABS resin casing (HB) in which no metal parts remained in the metal detection process was crushed by a crusher (screen mesh size: 8 mm).
[0043]
(Metal separation process)
The ABS resin casing (hereinafter referred to as a crushed material) crushed in the crushing process is placed on the installation part of a magnet bar (two-stage, five types, manufactured by Yamasan Co., Ltd.) whose residual magnetic flux density is 12,000 gauss. The metal powder mixed in the crushed material was separated and removed by passing it through.
[0044]
(Crushing material separation process)
The crushed material which passed through the metal separation step was separated and removed using a sieve having a 5 mm mesh.
[0045]
As described above, a recycled resin mainly composed of ABS resin was produced as a crushed material A having a size of 5 to 8 mm.
[0046]
<Residual investigation of unnecessary materials>
It was investigated whether or not unnecessary materials were mixed in the crushed material A produced as described above. First, unnecessary materials other than metal were examined visually but were not confirmed. Next, the unnecessary metal was investigated by passing the crushed material A through a lattice magnet stacked in two stages, but it was not confirmed.
[0047]
<Examination of mixed materials>
First, a disc (diameter 15 mm, thickness 0.5 mm) was produced by hot pressing using the crushed material A produced as described above, and the color tone of the disc was examined. As a result, it was confirmed that the disc had roughly four color distributions: ivory, light gray, gray and dark gray. In addition, it is considered that the gray color is caused by burning or dirt at the stage of manufacturing the disc. Next, samples were taken from the portions showing the respective colors, and the components of the samples were analyzed using an FT-IR analyzer (trade name: Spectrum, manufactured by Perkin Elmer Co., Ltd.). As a result, each color sample was an ABS resin.
[0048]
<Pellet productivity survey>
The pulverized material A produced as described above was examined for the extrusion state when pelletized using a twin-screw extrusion kneader (trade name: KZW-15, manufactured by Technobel Co., Ltd.) having a stirring blade. As a result, when the crushed material A was used, pellets could be produced in a very stable state without causing surging. This is considered to be due to the small variation in the size of the crushed material A (5 to 8 mm). Surging means that when the crushed material is kneaded while being heated, the crushed material is large so that the stirring blade stops due to biting, or conversely, the crushed material is small and the stirring blade is idled. This means that the rotation of the lens becomes uneven.
[0049]
<Production of resin material>
Using the crushed material A produced as described above, three types of resin materials (resin material 1 to resin material 3) were produced as molding materials. The resin material 1 is obtained by mixing 20 wt% of the crushed material A and 80 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material. Resin material 2 is 20 wt% of crushed material A, 35 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material, and 35 wt% of PC resin (trade name: A1900, manufactured by Idemitsu Kosan Co., Ltd.). , Phosphorus flame retardant (trade name: ADK STAB, manufactured by Asahi Denka Kogyo Co., Ltd.) is mixed at 10 wt%. Resin material 3 is 20 wt% of crushed material A, 30 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Co., Ltd.) as a virgin material, and 30 wt% of PC resin (trade name: A1900, manufactured by Idemitsu Kosan Co., Ltd.). 10 wt% of a phosphorus-based flame retardant (trade name: ADK STAB, manufactured by Asahi Denka Kogyo Co., Ltd.) and 10 wt% of glass fiber (trade name: CS 03 MA FT737, manufactured by Asahi Fiber Glass Co., Ltd.). Each material composition is shown in FIG. Next, resin materials 1 to 3 were melt-kneaded at about 230 ° C. using a twin-screw extrusion kneader (trade name: KZW-15, manufactured by Technobel Co., Ltd.). Furthermore, the melt-kneaded resin materials 1 to 3 were each pelletized using a strand cut pelletizer (trade name: SCP-102, manufactured by Technobel Co., Ltd.).
[0050]
<Production of resin molding>
From the pellets of the resin materials 1 to 3 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), molded body samples 1 to 3 (respectively lengths). 126 mm, width 12.8 mm, thickness 3.2 mm).
[0051]
<Measurement of bending strength>
The bending strength was measured about the molded object samples 1-3 produced as mentioned above. Specifically, using a universal testing machine (trade name: Instron 5581, manufactured by Instron Japan), a three-point bending test was performed on each of the molded body samples 1 to 3 in accordance with JIS K 7055. The bending strength of the molded body sample was measured by setting the distance (span) between the two support points to 51.2 mm and applying a pressing force to the approximate center between the two support points. As a result, the molded body sample 1 830kgf / cm ^2, the molded body sample 2 981kgf / cm ^2, the molded body sample 3 showed a bending strength of 1020kgf / cm ^2. These results are shown in FIG. The bending strength of the resin material is desirably 800 kgf / cm ² or more.
[0052]
<Measurement of flexural modulus>
The bending elastic modulus was measured about the molded object samples 1-3 produced as mentioned above. Specifically, a bending elastic modulus test was performed on each of the molded body samples 1 to 3 in accordance with JIS K 7055 using a universal testing machine (trade name: Instron 5581, manufactured by Instron Japan). The bending elastic modulus of the molded body sample was measured by setting the distance (span) between the two support points to 51.2 mm and applying a pressing force to the approximate center between the two support points. As a result, the molded body sample 1 29600kgf / cm ^2, the molded body sample 2 34200kgf / cm ^2, the molded body sample 3 exhibited a flexural modulus of 48000kgf / cm ^2. These results are shown in FIG. In addition, it is desirable that the flexural modulus of the resin material is 25000 kgf / cm ² or more.
[0053]
<Izod impact test>
Using pellets of resin materials 1 to 3 obtained as described above, an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.) is used for an Izod impact test in accordance with JIS K 7110. Izod impact test specimens 1 to 3 (each 126 mm long, 12.8 mm wide, 3.2 mm thick, and 2.54 mm deep notch depth in the thickness direction) were molded to form Izod impacts. The test specimens 1 to 3 were examined for impact resistance. Specifically, an Izod impact test was performed in accordance with JIS K 7110 using an Izod impact tester (trade name: Impact Tester, manufactured by Toyo Seiki Seisakusho Co., Ltd.). The Izod impact value in flatwise impact was 11 kgfcm / cm for the test piece 1 for Izod impact test, 18 kgfcm / cm for the test piece 2 for Izod impact test, and 35 kgfcm / cm for the test piece 3 for Izod impact test. These results are shown in FIG. It should be noted that the Izod impact strength of the resin material is desirably 8 kgfcm / cm or more.
[0054]
<Evaluation of fluidity>
Resin material obtained as described above using a bar flow mold that defines a cavity (full length of flow path: 1650 mm, width of flow path: 10 mm, thickness of flow path: 1 mm, mold temperature: 120 ° C.) The flow length was measured when the molten resin materials 1 to 3 obtained by melting the pellets 1 to 3 at 220 ° C. were injection molded at an injection pressure of 1600 kgf / cm ² . As a result, the molten resin material 1 showed a flow length of 160 mm, the molten resin material 2 of 161 mm, and the molten resin material 3 of 161 mm. These results are shown in FIG. Note that the flow length of the resin material is desirably 150 mm or more.
[0055]
<Evaluation of flame retardancy>
From the pellets of the resin materials 1 to 3 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), test pieces for combustion test 1 to 3 (125 mm × 13 mm × 1 mm) and a combustion test was performed. Specifically, according to a method based on the UL94 vertical combustion test method, a burn test is performed by bringing a burner flame of about 2.5 cm into contact with each test piece in a UL combustion test chamber (trade name: HVUL, manufactured by Toyo Seiki). And flame retardancy was evaluated. These results are shown in FIG.
[0056]
<Measurement of color difference>
The molded product samples 1 to 3 produced as described above are subjected to a color difference meter (trade name: CM-2600d, manufactured by Minolta Co., Ltd.), and the color difference (ΔE) from the color tone of the molded product samples 1 to 3 using white as the color difference standard. Was measured. As a result, the molded product sample 1 showed a color difference of 1.2, the molded product sample 2 showed a color difference of 1.8, and the molded product sample 3 showed a color difference of 1.8. These results are shown in FIG. In addition, as a resin material, it is desirable that a color difference is 2 or less.
[0057]
<Appearance evaluation>
By observing the appearance of the molded body samples 1 to 3 produced as described above, the quality of each molded body sample was evaluated from the degree of occurrence of sink marks and flashes (good: ◯, no: x). . These results are shown in FIG.
[0058]
<Evaluation of paintability>
The quality of the paintability of each molded body sample (good: ◯, no: x) was evaluated from the coating state when the molded body samples 1 to 3 produced as described above were coated. These results are shown in FIG.
[0059]
<Investigation of foreign matter residue>
Using resin materials 1 to 3, sample disks 1 to 3 (diameter 15 mm, thickness 0.5 mm) are prepared by hot pressing, and a foreign substance (black) can be visually recognized by observing the appearance of the sample disks 1 to 3 The number of those having a diameter of 0.2 mm or more and one having a diameter of 0.1 mm or more and less than 0.2 mm was counted. In the sample disc 1, 0 foreign matter having a diameter of 0.2 mm or more was detected per disc, and 1 foreign matter having a diameter of 0.1 mm or more and less than 0.2 mm was detected per disc. In the sample disc 2, 0 foreign matter having a diameter of 0.2 mm or more was detected per disc, and 2 foreign matters having a diameter of 0.1 mm or more and less than 0.2 mm were detected per disc. In the sample disk 3, 0 foreign matter having a diameter of 0.2 mm or more was detected per disc and 2 foreign matters having a diameter of 0.1 mm or more and less than 0.2 mm were detected per disc. These results are shown in FIG. In evaluating foreign matter, foreign matter having a diameter of 0.2 mm or more (dot-like dirt) is not included, and no more than two foreign matters have a diameter of 0.1 mm or more and less than 0.2 mm. It is desirable that
[0060]
[Comparative example]
<Production of recycled resin>
In this comparative example, in the flow shown in FIG. 6, the collection including a resin case made of a resin selected from the group consisting of acrylonitrile-butadiene-styrene (ABS) resin, polycarbonate resin, and polystyrene resin is mixed. A recycled resin containing ABS resin as a main component was produced from a product (desktop personal computer, printer, etc.).
[0061]
(Demolition collection process S1 ')
The recovered product was disassembled and the resin casing was recovered.
[0062]
(Removal step S2 ′)
Unnecessary substances remaining in the resin casing recovered in the dismantling and recovery step S1 ′ were removed. Specifically, the labels and rubber feet were scraped off with a spatula, the screws and springs were removed, and the embedded boss was cut off together with the surrounding resin. Moreover, the dust adhering to the resin case was blown off with an air gun, and the dirt not blown off was wiped off with a cloth. Resin casings that could not be wiped off were removed from the recycled resin manufacturing process.
[0063]
(S31 ′ of material discrimination step S3 ′)
In the material display engraved on the resin casing, the material indicated as “ABS resin” was extracted.
[0064]
(S32 ′ of combustion test step S3 ′)
The flame retardancy was determined in the same manner as in the example. Then, an ABS resin casing (HB), fractionated into the ABS resin casing (V -2), the ABS resin casing (V -2) from the manufacturing process of the recycled resin as being added flame retardant Removed.
[0065]
(S33 ′ of color difference identification step S3 ′)
An ABS resin casing (HB) that was judged to be white based on the naked eye was extracted.
[0066]
(Crushing step S5 ′)
The ABS resin casing that had undergone the color difference identification process described above was crushed by a crusher (screen mesh size: 20 mm).
[0067]
As described above, a recycled resin containing ABS resin as a main component was produced as a crushed material B having a size of 20 mm or less.
[0068]
<Residual investigation of unnecessary materials>
It was investigated whether or not unnecessary materials remained in the crushed material B produced as described above. First, unnecessary materials other than metal were examined visually. As a result, it was confirmed that deposits such as labels remained. Next, the unnecessary metal was investigated by passing the crushed material through a lattice magnet stacked in two stages. As a result, it was confirmed that the metal, which is considered to be derived from the embedded boss, remained.
[0069]
<Examination of mixed materials>
First, a disc (diameter 15 mm, thickness 0.5 mm) was produced by hot pressing using the crushed material B produced as described above, and the color tone of the disc was examined. As a result, it was confirmed that the disc had roughly four color distributions: ivory, light gray, gray and dark gray. In addition, it is considered that the gray color is caused by burning or dirt at the stage of manufacturing the disc. Next, samples were taken from the portions showing the respective colors, and the components of the samples were analyzed using an FT-IR analyzer (trade name: Spectrum, manufactured by Perkin Elmer Co., Ltd.). As a result, each color sample was ABS resin, but high impact polystyrene resin was also detected from the light gray portion and dark gray portion samples. This is considered to materials described in the material displayed in the material determination step and if you find that it is not described only a main ingredient, was going to not sufficiently prevent the contamination of other materials.
[0070]
<Pellet productivity survey>
The extrusion state at the time of pelletizing the crushed material B produced as described above using a twin-screw extrusion kneader (trade name: KZW-15, manufactured by Technobel Co., Ltd.) having a stirring blade was examined. As a result, when the crushed material B was used, clogging occurred in the twin-screw extrusion kneader, making it difficult to produce uniform pellets. This is considered to be due to the fact that the size variation of the crushed material is large (20 mm or less) and the maximum value (20 mm) of the size of the crushed material B is large.
[0071]
<Production of resin material>
Using the crushed material B produced as described above, a resin material 4 as a molding material was produced, and a resin material 5 made of only a virgin material was also produced. The resin material 4 is obtained by mixing 20 wt% of the crushed material B and 80 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material. Moreover, the resin material 5 is 100 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material. The composition of each material is shown in FIG. Next, the resin materials 4 to 5 were each pelletized in the same manner as in the example.
[0072]
<Production of resin molding>
From the pellets of the resin materials 4 to 5 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), molded body samples 4 to 5 (respectively lengths). 126 mm, width 12.8 mm, thickness 3.2 mm).
[0073]
<Measurement of bending strength>
About the molded object samples 4-5 produced as mentioned above, bending strength was measured like the Example. As a result, the molded body sample 4 showed a bending strength of 750 kgf / cm ² , and the molded body 5 showed a bending strength of 840 kgf / cm ² . These results are shown in FIG.
[0074]
<Measurement of flexural modulus>
About the molded object samples 4-5 produced as mentioned above, the bending elastic modulus was measured like the Example. As a result, the molded product sample 4 showed a flexural modulus of 24000 kgf / cm ² , and the molded product sample 5 showed a flexural modulus of 30000 kgf / cm ² . These results are shown in FIG.
[0075]
<Izod impact test>
From the pellets of the resin materials 4 to 5 obtained as described above, Izod impact test specimens 4 to 5 (length 126 mm, width 12.8 mm, thickness 3.2 mm, respectively) in the same manner as in the examples. A notch having a depth in the thickness direction of 2.54 mm) was molded and the impact resistance of the Izod impact test specimens 4 to 5 was examined. The Izod impact value in flatwise impact was 6 kgfcm / cm for the Izod impact test specimen 4 and 11 kgfcm / cm for the Izod impact test specimen 5. These results are shown in FIG.
[0076]
<Evaluation of fluidity>
In the same manner as in the example, the flow length was measured when the molten resin materials 4 to 5 obtained by melting the pellets of the resin materials 4 to 5 at 220 ° C. were injection molded at an injection pressure of 1600 kgf / cm ² . As a result, the molten resin material 4 showed a flow length of 142 mm, and the molten resin material 5 showed a flow length of 153 mm. These results are shown in FIG.
[0077]
<Evaluation of flame retardancy>
From the pellets of the resin materials 4 to 5 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), test pieces for combustion test 4 to 5 (125 mm × 13 mm × 1 mm), a combustion test was performed, and the flame retardancy was evaluated. These results are shown in FIG.
[0078]
<Measurement of color difference>
The molded product samples 4 to 5 produced as described above are subjected to a color difference meter (trade name: CM-2600d, manufactured by Minolta Co., Ltd.), and the color difference (ΔE) from the color tone of the molded product samples 4 to 5 using white as the color difference standard. Was measured. As a result, the molded product sample 4 showed a color difference of 2.4, and the molded product sample 5 showed a color difference of 1.1. These results are shown in FIG.
[0079]
<Appearance evaluation>
By observing the appearance of the molded body samples 4 to 5 produced as described above, the quality of each molded body sample was evaluated from the degree of occurrence of sink marks and flashes (good: ◯, no: x). . These results are shown in FIG.
[0080]
<Evaluation of paintability>
The quality (good: ◯, no: x) of the paintability of each molded body sample was evaluated from the coating state when the molded body samples 4 to 5 produced as described above were coated. These results are shown in FIG.
[0081]
<Investigation of foreign matter residue>
Using resin materials 4 to 5 , sample disks 4 to 5 (diameter 15 mm, thickness 0.5 mm) were prepared by hot pressing, and foreign matters (black color) visible by observing the appearance of the sample disks 4 to 5 The number of those having a diameter of 0.2 mm or more and one having a diameter of 0.1 mm or more and less than 0.2 mm was counted. As a result, in the sample disk 4, five foreign matters having a diameter of 0.2 mm or more were detected per disc, and 23 foreign matters having a diameter of 0.1 mm or more and less than 0.2 mm were detected per disc. The sample disk 5 detected 0 foreign matter having a diameter of 0.2 mm or more per disk and 0.5 foreign matter having a diameter of 0.1 mm or more and less than 0.2 mm per disk. These results are shown in FIG.
[0082]
<Evaluation>
As shown in FIG. 5, when the physical properties of the resin material 1 and the physical properties of the resin material 4 are compared, the resin material 4 including the recycled resin (crushed material B) obtained by the conventional manufacturing method has a physical property of resin. not reach the reference desired as material, a resin material 1 comprising a recycled resin obtained by the production method according to the present invention (crushed material a) has resulted in physical properties meet all predetermined criteria. Further, compared with the physical properties of the resin material 5 made only of the virgin material, the physical properties of the resin material 1 were almost the same, and the physical properties of the resin materials 2 and 3 were both higher than the resin material 5.
[Brief description of the drawings]
[Figure 1]
FIG. 1 is a flowchart showing a process for producing a recycled resin according to an embodiment of the present invention.
[Figure 2]
FIG. 2 is a diagram showing an example of a resin molded body that is dismantled and collected in the dismantling and collecting step.
[Fig. 3]
FIG. 3 is a view showing an example of a resin molded body that has undergone the removal step.
[Fig. 4]
FIG. 4 is a diagram showing the composition of the resin material produced in the examples and comparative examples of the present invention.
[Figure 5]
FIG. 5 is a table summarizing the physical properties and evaluation results of the resin materials produced in Examples and Comparative Examples of the present invention.
[Fig. 6]
FIG. 6 is a flowchart of a conventional recycled resin material manufacturing method.

  The present invention relates to a method for regenerating a resin from a resin molded body included in an electronic device, a home appliance, an interior, and the like. Furthermore, the present invention also relates to a resin material containing a regenerated resin obtained by the method.

  In recent years, laws related to resource countermeasures such as the establishment of the Law on Effective Utilization of Resources have progressed, and efforts to recycle products, reuse resources, and reduce waste have become active. In particular, collection and recycling of sold products have become an important issue for manufacturers of home appliances and electronic devices.

  For example, in various personal computers, printers, mobile phones, and the like, a resin material is often used as a material constituting the housing from the viewpoint of moldability and lightness. Therefore, in such a field, establishment of a resin casing recycling technique is strongly desired.

Resin casing recycling technology includes thermal recycling technology that uses the resin casing as a heat source, and cascade usage that requires relatively no reduction in physical properties of recycled resin obtained by recycling the resin casing. Recycling technology. Below, an example of the manufacturing method of the recycled resin in the recycling technique for cascade utilization is demonstrated concretely, referring FIG. First, various collected personal computers, printers, mobile phones and the like are disassembled, and the resin casings included in these are separated and collected (disassembly collection step S1 ′). Next, from the separated and collected resin casing, adhering matters such as labels and rubber feet, metal parts such as screws and springs, and unnecessary items such as dirt such as dust and dirt are removed (removal step S2 ′). Next, the material of the resin casing from which unnecessary materials have been removed is discriminated by the material display shown on the resin casing (material discriminating step S31 ′), and difficult by a flame retardant test (for example, UL94 combustion test method). The presence or absence of the addition of the fuel is discriminated ( combustion test step S32 ′), and the color difference is identified by the naked eye (color difference identifying step S33 ′) to perform classification (sorting step S3 ′). Next, the sorted resin casing is crushed by a crusher (crushing step S5 ′). Through these steps, recycled resin can be obtained from recovered products (such as various personal computers).

  However, since the degree of deterioration of the resin contained in the resin casing varies greatly depending on the use state of the recovered product, etc., the resin material containing the recycled resin obtained by the recycling technique as shown in FIG. Thus, it has been difficult to stably obtain the same physical properties and aesthetics as the virgin resin material. Therefore, it has been difficult to use a resin material containing recycled resin as a molding material for a resin casing (for example, a resin casing constituting a recovered product) that requires high fluidity and high strength. .

  Therefore, techniques that can obtain the physical properties of a resin material containing a recycled resin obtained by a recycling technique at the same level as that of a virgin resin material are disclosed in Japanese Patent Application Laid-Open Nos. 2000-198116 and 2001-30248. Is known.

  However, since the techniques disclosed in Japanese Patent Laid-Open Nos. 2000-198116 and 2001-30248 do not select the material of the resin casing of the recovered product, there are various types of resin casing materials of the recovered product. When these are mixed, it becomes difficult to maintain the physical properties of the resin material including the recycled resin obtained by the recycling technique at the same level as the virgin resin material. Moreover, although metal separation processes, such as a magnetic fractionation process, are performed in multiple times, all processes are performed after the crushing process. Therefore, in the crushing process of crushing the resin casing with the crusher, if metal parts remain, the metal parts are also crushed together with the resin casing, and damage to the crusher is increased. In addition, since the amount of metal to be removed after crushing is relatively large, the amount of the resin that is removed together with the metal by adhering to the metal increases, and the resin recovery efficiency may decrease.

  Therefore, the object of the present invention is to obtain the same physical properties and aesthetics as each virgin resin material by separating the materials even when various materials are mixed as the material of the resin casing of the recovered product, and An object of the present invention is to provide a method for producing a recycled resin capable of suppressing a reduction in resin recovery efficiency and reducing damage to a crusher in a crushing step.

  Another object of the present invention is to provide a resin material containing a recycled resin produced by such a production method.

  The method for producing a recycled resin according to the first aspect of the present invention includes dismantling a product having a resin molded body, recovering the resin molded body, and removing unnecessary materials including metal parts from the resin molded body. In a recycled resin manufacturing method including a removing step, a separating step for determining the material of the resin molded body, and a crushing step for crushing the resin molded body, a metal detector that detects a metal part as a pre-process of the crushing step And a metal separation step of separating and removing a metal component remaining in the crushed material obtained in the crushing step from the crushed material as a subsequent step of the crushing step.

  According to such a method, even if the resin molded body recovered from the product is made of various materials, the resin molded body can be sorted for each material in the sorting step. Therefore, it is possible to stabilize the physical properties of the obtained recycled resin by manufacturing the recycled resin for each sorted material. In addition, by reducing the metal content in the metal detection process, metal content is mixed in the produced recycled resin, and the reduction in impact strength due to the formation of a discontinuous phase in the mixed portion is suppressed. In addition to being able to, it is possible to suppress the occurrence of poor appearance. Therefore, the physical properties of the resin material including the recycled resin produced by the method of the present invention should be maintained at the same level as that of the virgin resin material even when various types of resin molded materials are mixed. Is possible.

  By providing the metal detection process before the crushing process, the possibility that metal parts and the like remain on the resin molded body to be crushed in the crushing process is further reduced. Therefore, for example, even when the resin molded body is crushed using a crusher provided with a blade portion, blade spillage of the blade portion is less likely to occur. Therefore, damage to the crusher can be reduced. In addition, since the amount of metal to be removed in the metal separation step is reduced, the amount of resin that is removed together with the metal by attaching to the metal is reduced. Therefore, it is possible to suppress a decrease in resin recovery efficiency.

Preferably, the separation step further includes a combustion test step for measuring the flame retardancy of the resin molded body. By adding such a step, it becomes possible to determine whether or not the flame retardant is contained in the resin molded body. When the flame retardant is contained in the resin molded body, the following problems may occur when the recycled resin is manufactured. For example, when a phosphorus-based flame retardant is included, physical properties may deteriorate, such as the flowability of the recycled resin being increased more than necessary, and when a halogen-based flame retardant is included, the recycled resin This is undesirable from an environmental point of view. Therefore, in the combustion test process, the presence or absence of a flame retardant is determined, and the resin molded product containing the flame retardant is separated and removed, thereby stabilizing the physical properties of the produced recycled resin and improving the environmental resistance. Can do.

  Preferably, the separation step further includes a color difference measurement step for measuring the color difference of the resin molded body. By adding such a process, it becomes possible to control the color tone of the resin after regeneration. As a result, for example, it is possible to selectively produce a recycled resin having a color tone close to white and rich in versatility, or a recycled resin having a color tone close to that of a virgin resin. Therefore, the color tone can be maintained at the same level as the virgin resin material.

Furthermore, the manufacturing method of the recycled resin may further include a crushed material separation step of separating the crushed material that has undergone the metal separation step using a sieve having a mesh size of 1 to 5 mm. By providing such a process, it becomes possible to separate and remove crushed materials having a size of 1 to 5 mm or less. By removing the crushed material having a size of 1 to 5 mm or less, the distribution range of the size of the crushed material can be narrowed. Therefore, when kneading the crushed material, kneading can be performed more uniformly. In addition, since it is possible to remove fine foreign matters that could not be removed in the removal step or the metal separation step, it is possible to produce a recycled resin with more stable physical properties.

  Preferably, the detection of the metal part in the metal detection process is performed using a metal detector. As a result, the metal part can be detected more reliably than by visual observation, so that the possibility of the metal part remaining can be reduced more thoroughly.

  Preferably, the metal separation step is performed by magnetic separation using magnetic force. By providing the metal separation step, it is possible to suppress the metal component from being mixed into the recycled resin. Therefore, it is possible to suppress a reduction in impact strength due to the presence of a metal component in the recycled resin and the formation of a discontinuous phase in the mixed portion. Further, by thoroughly removing the metal component, it is possible to suppress appearance defects. The magnetic separation is preferably performed using a magnet having a magnetic force with a residual magnetic flux density of the magnetic pole portion of 10,000 gauss or more.

  According to the 2nd side surface of this invention, the resin material containing the reproduction | regeneration resin manufactured by the above manufacturing methods and a virgin resin is provided.

  Preferably, the resin material further includes a filler and / or a flame retardant selected from the group consisting of glass fiber, carbon fiber, glass flake, glass bead, mica, talc and rubber. Thereby, physical properties such as strength and expansion coefficient of the resin material can be adjusted.

  Hereinafter, the manufacturing method of the recycled resin which concerns on embodiment of this invention is demonstrated concretely, referring FIGS. 1-5.

  FIG. 1 is a flowchart showing a series of steps from disassembly and collection of collected products (for example, various personal computers and printers) to production of recycled resin. Through these steps, a resin material of a predetermined material can be regenerated from various recovered products. FIG. 2 is a view showing an example of a resin molded body disassembled and collected from a collected product (a part of a case of a desktop personal computer).

  In the dismantling and recovery step S1, the resin molded body (see FIG. 2) is recovered from the recovered product by disassembling the recovered product having the resin molded body. Examples of collected products include various personal computers and peripheral devices (printers, keyboards, displays, etc.), electronic devices such as copiers, home appliances, interiors, and the like that have resin moldings. The material of the resin molding is acrylonitrile-butadiene-styrene (ABS) resin, polycarbonate (PC) resin, polyphenyl ether (PPE) resin, polyamide (PA) resin, liquid crystal polymer (LCP) resin, polylactic acid (PLA) Examples thereof include resins such as resins, polyethylene terephthalate (PET) resins, polyphenylene sulfide (PPS) resins, polyacetal (POM) resins, polystyrene (PS) resins, and resin alloys containing these resins.

  In the removal step S2, as shown in FIG. 3, the unnecessary material 1 remaining in the resin molded body (see FIG. 2) recovered in the dismantling and recovery step S1 is removed. Examples of the unnecessary material include a deposit 10 such as a label and a rubber foot, a metal part 11 such as a screw and an embedded boss, and dirt such as dust and dirt.

  Specific methods for removing the unwanted material 1 include the following. In the case of the deposit 10, the deposit 10 is scraped off with a spatula or the like, or is scraped off using a grinder such as a grinder. In the case of the metal part 11, screws and springs are removed manually, and embedded bosses and the like are cut off for the surrounding resin in consideration of work efficiency. If it is dirty, blow it away with an air gun, or wipe away anything that won't fly with an air gun. If dirt (such as highly adhesive grease) that does not blow off with an air gun and cannot be wiped off with a cloth remains in the resin molding, exclude the resin molding from the manufacturing process, for example, thermal recycling It is preferable to perform (such as melting the resin and separating the dirt).

  The separation step S3 includes a material discrimination step S31, a combustion test step S32, and a color difference measurement step S33, and the resin molded body is separated based on the material, the presence / absence of a flame retardant, and the color tone. In parallel with the separation, a check is also performed to determine whether or not the unnecessary material 1 remains on the resin molded body by visual inspection or the like. If the residual of the unnecessary material 1 is confirmed (NG), the resin molded body is removed. Feedback is provided to step S2. On the other hand, when the residue of the unwanted material 1 is not confirmed (OK), the resin molded body is moved to the next step.

  In the material discrimination step S31, the material of the resin molded body is discriminated. As this discrimination method, there is a method in which the resin molded body is applied to a material discriminator in order to discriminate the material in more detail and surely after being roughly classified for each material display stamped on the resin molded body. In the case of such a method, the resin molded body can be more reliably classified for each material (for example, ABS resin, PC resin, etc.). Therefore, even when the resin is regenerated from the resin molded body in which various materials are mixed, the physical properties of the regenerated resin can be stabilized.

  In the combustion test step S32, it is determined whether or not the flame retardant is contained in the resin molded body. As a method for this determination, after confirming the presence or absence of a flame retardant from the display stamped on the resin molded body, and classifying it, a resin molded body that does not display the presence or absence of the flame retardant, and an indication that the flame retardant is not included Examples include a method in which a test piece is cut out from each of the resin molded bodies and the test piece is subjected to a flame retardancy test such as a UL94 combustion test method. When a recycled resin is produced using a resin molded body containing a flame retardant, if the flame retardant is a phosphorus flame retardant, physical properties such as a decrease in the molecular weight of the recycled resin may be caused. Moreover, when the said flame retardant is a halogenated flame retardant, when it mixes with a recycled resin, it is unpreferable from an environmental viewpoint. Therefore, it is preferable to exclude the resin molding confirmed to contain the flame retardant in the combustion test step S32 from the manufacturing process according to the present invention. However, when it is planned to add a flame retardant when producing a resin material containing a recycled resin produced by the production method according to the present invention, a resin molded article containing the flame retardant is used in the combustion test step S32. It does not have to be excluded.

  In the color difference measurement step S33, the color tone of the resin molded body is determined by measuring the color difference (ΔE) of the resin molded body with respect to the color difference standard. As this discrimination method, a color difference meter is used to measure the color difference with the color tone of the resin molded product using white as a color difference standard, and then classify according to the obtained color difference (ΔE). Generally, a color tone close to white (for example, ΔE ≦ 2) has a wider range of later coloration and is more versatile. Therefore, a resin molded product in which ΔE is 2 or less with white as a color difference standard and a resin larger than 2 It is preferable to separate into a molded body and treat each separately. The color difference (ΔE) is a value that quantitatively indicates the degree of color deviation from a color (for example, white) as a color difference standard, and means that the larger the value, the larger the color deviation.

  In the metal detection step S4, it is detected whether or not metal parts such as screws remain on the resin molded body. As this detection method, there is a method in which a metal detector is used to check the presence or absence of residual metal parts in the resin molded body. According to this method, since the metal part can be detected more reliably than by visual observation, the possibility of the metal part remaining can be reduced more thoroughly. In addition, when the residue of the metal part is confirmed in the resin molded body (NG), the resin molded body is fed back to the removal step S2, and when the residue of the metal part is not confirmed (OK), the resin molded body is the next process. Moved to.

  In the crushing step S5, the resin molded body in which the metal part has not been detected in the metal detection step S4 is crushed, and a crushed material RR is obtained. Examples of the crushing method include a method of crushing using a crusher equipped with a cover mesh having a predetermined mesh size until the size of the resin molded body is equal to or smaller than the mesh size. The mesh size is preferably 8 to 10 mm. When the mesh size is less than 8 mm, the amount of fine powder (for example, 5 mm or less) increases, so that the amount of the crushed material RR that is removed in the crushed material separation step S7 described later increases, and the recycling efficiency decreases. Further, when the mesh size is larger than 10 mm, the crushed material RR is too large, so that problems such as clogging are likely to occur in the subsequent processing, and the crushed material RR may not be kneaded uniformly. is there.

  In the metal separation step S6, the metal powder mixed in the crushed material RR is separated and removed. Examples of the separation / removal method include a method of separating and removing metal powder by magnetic separation using magnetic force. According to such a method, for example, even when the metal powder is mixed in the crushing step S5, the metal powder is removed in the metal separation step S6, so that the mixing of the metal powder into the recycled resin can be suppressed. Accordingly, it is possible to suppress a reduction in impact strength due to the presence of metal powder in the recycled resin and the formation of a discontinuous phase in the mixed portion. Moreover, since the metal powder of the size (for example, diameter is 0.2 mm or more) which can be visually recognized can be removed thoroughly, generation | occurrence | production of an external appearance defect can be suppressed. The magnetic separation is preferably performed using a magnet having a magnetic force with a residual magnetic flux density of the magnetic pole portion of 10,000 gauss or more.

In the crushed material separation step S7, the fine crushed material RR is separated and removed. Examples of the separation and removal method include a method of separating and removing the crushed material RR having a size of 1 to 5 mm or less using a sieve having a mesh size of 1 to 5 mm. According to such a method, it is possible not only to separate and remove the foreign matter (metal powder and the like) that could not be removed in the removal step S2 and the metal separation step S6 together with the fine crushed material RR, but also the crushed recycled resin. The size distribution range can be narrowed. Accordingly, a recycled resin having more stable physical properties can be obtained and the distribution range of the size of the recycled resin can be narrowed, so that the recycled resin can be kneaded in a more balanced manner (the distribution of the size of the recycled resin). Due to the narrow range, it becomes easier to obtain a more uniform resin.

  As described above, a recycled resin is produced from a resin molded body obtained by disassembling the recovered product. Further, by kneading the recycled resin and the virgin material, a resin material having physical properties equivalent to those of a resin made of only the virgin material can be obtained. Further, by adding a filler and / or a flame retardant selected from the group consisting of glass fiber, carbon fiber, glass flake, glass bead, mica, talc and rubber, a resin consisting of only a virgin material even if a regenerated resin is added It is also possible to obtain a resin material having physical properties superior to those of the material. In addition, although specific embodiment of this invention was described above, this invention is not limited to this, A various change is possible within the range which does not deviate from the thought of invention.

  Next, specific examples of the present invention will be described together with comparative examples.

[Example]
<Manufacture of recycled resin>
In this embodiment, in the flow shown in FIG. 1, the ABS resin is recovered from a collected product (desktop personal computer, printer, etc.) in which a resin casing made of any of ABS resin, PC resin and PS resin is mixed. A regenerated resin containing as a main component was prepared.

(Demolition collection process)
The recovered product was disassembled and the resin casing was recovered.

(Removal process)
Unnecessary substances remaining in the resin casing recovered in the dismantling and recovery step were removed. Specifically, the labels and rubber feet were scraped off with a spatula, the screws and springs were removed, and the embedded boss was cut off together with the surrounding resin. Moreover, the dust adhering to the resin case was blown off with an air gun, and the dirt not blown off was wiped off with a cloth. Resin casings that could not be wiped off were removed from the recycled resin manufacturing process.

(Material discrimination process)
First, what is displayed as “ABS resin” as a material in the material display stamped on the resin casing was extracted. Next, the resin casing without the material display and the resin casing with the display of “ABS resin” are applied to a material discriminator (trade name: PLID-3, manufactured by Toa Denpa Kogyo Co., Ltd.) to identify and check the material. Went. In addition, the resin casing in which the residue of the unnecessary thing was confirmed in the said process was fed back to the removal process.

(Combustion test process)
First, an ABS resin casing having a display indicating that a flame retardant is added to a resin casing (hereinafter referred to as an ABS resin casing) whose material is determined to be ABS resin in the material determining step is a process for producing recycled resin. Removed from. Next, a flame test was performed on the test piece cut out from the ABS resin casing without a display regarding the addition of the flame retardant by the UL 94 combustion test method to determine the flame retardancy. An ABS resin casing (hereinafter referred to as ABS resin casing (HB)) having flame retardancy of HB (UL94 standard) and an ABS resin casing (hereinafter referred to as ABS resin casing) of V-2 (UL94 standard) or higher. body (V -2) and referred) and fractionated into the ABS resin casing (V -2) was removed from the manufacturing process of the recycled resin as being added flame retardants. In addition, the resin casing in which the residue of the unnecessary thing was confirmed in the said process was fed back to the removal process.

(Color difference measurement process)
The ABS resin casing (HB) was subjected to a color difference meter (trade name: CM-2600d, manufactured by Minolta Co., Ltd.), and the color difference (ΔE) from the color tone of the ABS resin casing (HB) was measured using white as the color difference standard. Then, the ABS resin casing (HB) having a ΔE greater than 2 and the ABS resin casing (HB) having a ΔE of 2 or less were separated, and the ABS resin casing (HB) having a ΔE of 2 or less was extracted. In addition, the resin casing in which the residue of the unnecessary thing was confirmed in the said process was fed back to the removal process.

(Metal detection process)
A table metal detector (trade name: MS-3114-35S, Nisshin Denshi Kogyo Co., Ltd.) with an ABS resin casing (HB) having a ΔE of 2 or less after a separation process consisting of a material discrimination process, a combustion test process and a color difference measurement process. The ABS resin casing (HB) was examined for the presence of metal parts (screws, springs, embedded bosses, etc.). The resin casing in which the remaining metal parts were confirmed was fed back to the removal process.

(Crushing process)
The ABS resin casing (HB) in which no metal parts remained in the metal detection process was crushed by a crusher (screen mesh size: 8 mm).

(Metal separation process)
The ABS resin casing (hereinafter referred to as a crushed material) crushed in the crushing process is placed on the installation part of a magnet bar (two-stage, five types, manufactured by Yamasan Co., Ltd.) whose residual magnetic flux density is 12,000 gauss. The metal powder mixed in the crushed material was separated and removed by passing it through.

(Crushing material separation process)
The crushed material which passed through the metal separation step was separated and removed using a sieve having a 5 mm mesh.

  As described above, a recycled resin mainly composed of ABS resin was produced as a crushed material A having a size of 5 to 8 mm.

<Residual investigation of unnecessary materials>
It was investigated whether or not unnecessary materials were mixed in the crushed material A produced as described above. First, unnecessary materials other than metal were examined visually but were not confirmed. Next, the unnecessary metal was investigated by passing the crushed material A through a lattice magnet stacked in two stages, but it was not confirmed.

<Examination of mixed materials>
First, a disc (diameter 15 mm, thickness 0.5 mm) was produced by hot pressing using the crushed material A produced as described above, and the color tone of the disc was examined. As a result, it was confirmed that the disc had roughly four color distributions: ivory, light gray, gray and dark gray. In addition, it is considered that the gray color is caused by burning or dirt at the stage of manufacturing the disc. Next, samples were taken from the portions showing the respective colors, and the components of the samples were analyzed using an FT-IR analyzer (trade name: Spectrum, manufactured by Perkin Elmer Co., Ltd.). As a result, each color sample was an ABS resin.

<Pellet productivity survey>
The pulverized material A produced as described above was examined for the extrusion state when pelletized using a twin-screw extrusion kneader (trade name: KZW-15, manufactured by Technobel Co., Ltd.) having a stirring blade. As a result, when the crushed material A was used, pellets could be produced in a very stable state without causing surging. This is considered to be due to the small variation in the size of the crushed material A (5 to 8 mm). Surging means that when the crushed material is kneaded while being heated, the crushed material is large so that the stirring blade stops due to biting, or conversely, the crushed material is small and the stirring blade is idled. This means that the rotation of the lens becomes uneven.

<Production of resin material>
Using the crushed material A produced as described above, three types of resin materials (resin material 1 to resin material 3) were produced as molding materials. The resin material 1 is obtained by mixing 20 wt% of the crushed material A and 80 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material. Resin material 2 is 20 wt% of crushed material A, 35 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material, and 35 wt% of PC resin (trade name: A1900, manufactured by Idemitsu Kosan Co., Ltd.). , Phosphorus flame retardant (trade name: ADK STAB, manufactured by Asahi Denka Kogyo Co., Ltd.) is mixed at 10 wt%. Resin material 3 is 20 wt% of crushed material A, 30 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Co., Ltd.) as a virgin material, and 30 wt% of PC resin (trade name: A1900, manufactured by Idemitsu Kosan Co., Ltd.). 10 wt% of a phosphorus-based flame retardant (trade name: ADK STAB, manufactured by Asahi Denka Kogyo Co., Ltd.) and 10 wt% of glass fiber (trade name: CS 03 MA FT737, manufactured by Asahi Fiber Glass Co., Ltd.). Each material composition is shown in FIG. Next, resin materials 1 to 3 were melt-kneaded at about 230 ° C. using a twin-screw extrusion kneader (trade name: KZW-15, manufactured by Technobel Co., Ltd.). Furthermore, the melt-kneaded resin materials 1 to 3 were each pelletized using a strand cut pelletizer (trade name: SCP-102, manufactured by Technobel Co., Ltd.).

<Production of resin molding>
From the pellets of the resin materials 1 to 3 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), molded body samples 1 to 3 (respectively lengths). 126 mm, width 12.8 mm, thickness 3.2 mm).

<Measurement of bending strength>
The bending strength was measured about the molded object samples 1-3 produced as mentioned above. Specifically, using a universal testing machine (trade name: Instron 5581, manufactured by Instron Japan), a three-point bending test was performed on each of the molded body samples 1 to 3 in accordance with JIS K 7055. The bending strength of the molded body sample was measured by setting the distance (span) between the two support points to 51.2 mm and applying a pressing force to the approximate center between the two support points. As a result, the molded body sample 1 830kgf / cm ^2, the molded body sample 2 981kgf / cm ^2, the molded body sample 3 showed a bending strength of 1020kgf / cm ^2. These results are shown in FIG. The bending strength of the resin material is desirably 800 kgf / cm ² or more.

<Measurement of flexural modulus>
The bending elastic modulus was measured about the molded object samples 1-3 produced as mentioned above. Specifically, a bending elastic modulus test was performed on each of the molded body samples 1 to 3 in accordance with JIS K 7055 using a universal testing machine (trade name: Instron 5581, manufactured by Instron Japan). The bending elastic modulus of the molded body sample was measured by setting the distance (span) between the two support points to 51.2 mm and applying a pressing force to the approximate center between the two support points. As a result, the molded body sample 1 29600kgf / cm ^2, the molded body sample 2 34200kgf / cm ^2, the molded body sample 3 exhibited a flexural modulus of 48000kgf / cm ^2. These results are shown in FIG. In addition, it is desirable that the flexural modulus of the resin material is 25000 kgf / cm ² or more.

<Izod impact test>
Using pellets of resin materials 1 to 3 obtained as described above, an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.) is used for an Izod impact test in accordance with JIS K 7110. Izod impact test specimens 1 to 3 (each 126 mm long, 12.8 mm wide, 3.2 mm thick, and 2.54 mm deep notch depth in the thickness direction) were molded to form Izod impacts. The test specimens 1 to 3 were examined for impact resistance. Specifically, an Izod impact test was performed in accordance with JIS K 7110 using an Izod impact tester (trade name: Impact Tester, manufactured by Toyo Seiki Seisakusho Co., Ltd.). The Izod impact value in flatwise impact was 11 kgfcm / cm for the test piece 1 for Izod impact test, 18 kgfcm / cm for the test piece 2 for Izod impact test, and 35 kgfcm / cm for the test piece 3 for Izod impact test. These results are shown in FIG. It should be noted that the Izod impact strength of the resin material is desirably 8 kgfcm / cm or more.

<Evaluation of fluidity>
Resin material obtained as described above using a bar flow mold that defines a cavity (full length of flow path: 1650 mm, width of flow path: 10 mm, thickness of flow path: 1 mm, mold temperature: 120 ° C.) The flow length was measured when the molten resin materials 1 to 3 obtained by melting the pellets 1 to 3 at 220 ° C. were injection molded at an injection pressure of 1600 kgf / cm ² . As a result, the molten resin material 1 showed a flow length of 160 mm, the molten resin material 2 of 161 mm, and the molten resin material 3 of 161 mm. These results are shown in FIG. Note that the flow length of the resin material is desirably 150 mm or more.

<Evaluation of flame retardancy>
From pellets of resin materials 1 to 3 obtained as described above, an injection molding machine (trade name: SG
50, manufactured by Sumitomo Heavy Industries, Ltd.), test pieces for combustion test 1 to 3 (125 mm × 13 mm × 1 mm) were prepared and subjected to a combustion test. Specifically, according to a method based on the UL94 vertical combustion test method, a burn test is performed by bringing a burner flame of about 2.5 cm into contact with each test piece in a UL combustion test chamber (trade name: HVUL, manufactured by Toyo Seiki). And flame retardancy was evaluated. These results are shown in FIG.

<Measurement of color difference>
The molded product samples 1 to 3 produced as described above are subjected to a color difference meter (trade name: CM-2600d, manufactured by Minolta Co., Ltd.), and the color difference (ΔE) from the color tone of the molded product samples 1 to 3 using white as the color difference standard. Was measured. As a result, the molded product sample 1 showed a color difference of 1.2, the molded product sample 2 showed a color difference of 1.8, and the molded product sample 3 showed a color difference of 1.8. These results are shown in FIG. In addition, as a resin material, it is desirable that a color difference is 2 or less.

<Appearance evaluation>
By observing the appearance of the molded body samples 1 to 3 produced as described above, the quality of each molded body sample was evaluated from the degree of occurrence of sink marks and flashes (good: ◯, no: x). . These results are shown in FIG.

<Evaluation of paintability>
The quality of the paintability of each molded body sample (good: ◯, no: x) was evaluated from the coating state when the molded body samples 1 to 3 produced as described above were coated. These results are shown in FIG.

<Investigation of foreign matter residue>
Using resin materials 1 to 3, sample disks 1 to 3 (diameter 15 mm, thickness 0.5 mm) are prepared by hot pressing, and a foreign substance (black) can be visually recognized by observing the appearance of the sample disks 1 to 3 The number of those having a diameter of 0.2 mm or more and one having a diameter of 0.1 mm or more and less than 0.2 mm was counted. In the sample disc 1, 0 foreign matter having a diameter of 0.2 mm or more was detected per disc, and 1 foreign matter having a diameter of 0.1 mm or more and less than 0.2 mm was detected per disc. In the sample disc 2, 0 foreign matter having a diameter of 0.2 mm or more was detected per disc, and 2 foreign matters having a diameter of 0.1 mm or more and less than 0.2 mm were detected per disc. In the sample disk 3, 0 foreign matter having a diameter of 0.2 mm or more was detected per disc and 2 foreign matters having a diameter of 0.1 mm or more and less than 0.2 mm were detected per disc. These results are shown in FIG. In evaluating foreign matter, foreign matter having a diameter of 0.2 mm or more (dot-like dirt) is not included, and no more than two foreign matters have a diameter of 0.1 mm or more and less than 0.2 mm. It is desirable that

[Comparative example]
<Production of recycled resin>
In this comparative example, in the flow shown in FIG. 6, the collection including a resin case made of a resin selected from the group consisting of acrylonitrile-butadiene-styrene (ABS) resin, polycarbonate resin, and polystyrene resin is mixed. A recycled resin containing ABS resin as a main component was produced from a product (desktop personal computer, printer, etc.).

(Demolition collection process S1 ')
The recovered product was disassembled and the resin casing was recovered.

(Removal step S2 ′)
Unnecessary substances remaining in the resin casing recovered in the dismantling and recovery step S1 ′ were removed. Specifically, the labels and rubber feet were scraped off with a spatula, the screws and springs were removed, and the embedded boss was cut off together with the surrounding resin. Moreover, the dust adhering to the resin case was blown off with an air gun, and the dirt not blown off was wiped off with a cloth. Resin casings that could not be wiped off were removed from the recycled resin manufacturing process.

(S31 ′ of material discrimination step S3 ′)
In the material display engraved on the resin casing, the material indicated as “ABS resin” was extracted.

(S32 ′ of combustion test step S3 ′)
The flame retardancy was determined in the same manner as in the example. Then, an ABS resin casing (HB), fractionated into the ABS resin casing (V -2), the ABS resin casing (V -2) from the manufacturing process of the recycled resin as being added flame retardant Removed.

(S33 ′ of color difference identification step S3 ′)
An ABS resin casing (HB) that was judged to be white based on the naked eye was extracted.

(Crushing step S5 ′)
The ABS resin casing that had undergone the color difference identification process described above was crushed by a crusher (screen mesh size: 20 mm).

  As described above, a recycled resin containing ABS resin as a main component was produced as a crushed material B having a size of 20 mm or less.

<Residual investigation of unnecessary materials>
It was investigated whether or not unnecessary materials remained in the crushed material B produced as described above. First, unnecessary materials other than metal were examined visually. As a result, it was confirmed that deposits such as labels remained. Next, the unnecessary metal was investigated by passing the crushed material through a lattice magnet stacked in two stages. As a result, it was confirmed that the metal, which is considered to be derived from the embedded boss, remained.

<Examination of mixed materials>
First, a disc (diameter 15 mm, thickness 0.5 mm) was produced by hot pressing using the crushed material B produced as described above, and the color tone of the disc was examined. As a result, it was confirmed that the disc had roughly four color distributions: ivory, light gray, gray and dark gray. In addition, it is considered that the gray color is caused by burning or dirt at the stage of manufacturing the disc. Next, samples were taken from the portions showing the respective colors, and the components of the samples were analyzed using an FT-IR analyzer (trade name: Spectrum, manufactured by Perkin Elmer Co., Ltd.). As a result, each color sample was ABS resin, but high impact polystyrene resin was also detected from the light gray portion and dark gray portion samples. This is considered to materials described in the material displayed in the material determination step and if you find that it is not described only a main ingredient, was going to not sufficiently prevent the contamination of other materials.

<Pellet productivity survey>
The extrusion state at the time of pelletizing the crushed material B produced as described above using a twin-screw extrusion kneader (trade name: KZW-15, manufactured by Technobel Co., Ltd.) having a stirring blade was examined. As a result, when the crushed material B was used, clogging occurred in the twin-screw extrusion kneader, making it difficult to produce uniform pellets. This is considered to be due to the fact that the size variation of the crushed material is large (20 mm or less) and the maximum value (20 mm) of the size of the crushed material B is large.

<Production of resin material>
Using the crushed material B produced as described above, a resin material 4 as a molding material was produced, and a resin material 5 made of only a virgin material was also produced. The resin material 4 is obtained by mixing 20 wt% of the crushed material B and 80 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material. Moreover, the resin material 5 is 100 wt% of ABS resin (trade name: VD200, manufactured by UMGABS Corporation) as a virgin material. The composition of each material is shown in FIG. Next, the resin materials 4 to 5 were each pelletized in the same manner as in the example.

<Production of resin molding>
From the pellets of the resin materials 4 to 5 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), molded body samples 4 to 5 (respectively lengths). 126 mm, width 12.8 mm, thickness 3.2 mm).

<Measurement of bending strength>
About the molded object samples 4-5 produced as mentioned above, bending strength was measured like the Example. As a result, the molded body sample 4 showed a bending strength of 750 kgf / cm ² , and the molded body 5 showed a bending strength of 840 kgf / cm ² . These results are shown in FIG.

<Measurement of flexural modulus>
About the molded object samples 4-5 produced as mentioned above, the bending elastic modulus was measured like the Example. As a result, the molded product sample 4 showed a flexural modulus of 24000 kgf / cm ² , and the molded product sample 5 showed a flexural modulus of 30000 kgf / cm ² . These results are shown in FIG.

<Izod impact test>
From the pellets of the resin materials 4 to 5 obtained as described above, Izod impact test specimens 4 to 5 (length 126 mm, width 12.8 mm, thickness 3.2 mm, respectively) in the same manner as in the examples. A notch having a depth in the thickness direction of 2.54 mm) was molded and the impact resistance of the Izod impact test specimens 4 to 5 was examined. The Izod impact value in flatwise impact was 6 kgfcm / cm for the Izod impact test specimen 4 and 11 kgfcm / cm for the Izod impact test specimen 5. These results are shown in FIG.

<Evaluation of fluidity>
In the same manner as in the example, the flow length was measured when the molten resin materials 4 to 5 obtained by melting the pellets of the resin materials 4 to 5 at 220 ° C. were injection molded at an injection pressure of 1600 kgf / cm ² . As a result, the molten resin material 4 showed a flow length of 142 mm, and the molten resin material 5 showed a flow length of 153 mm. These results are shown in FIG.

<Evaluation of flame retardancy>
From the pellets of the resin materials 4 to 5 obtained as described above, using an injection molding machine (trade name: SG50, manufactured by Sumitomo Heavy Industries, Ltd.), test pieces for combustion test 4 to 5 (125 mm × 13 mm × 1 mm), a combustion test was performed, and the flame retardancy was evaluated. These results are shown in FIG.

<Measurement of color difference>
The molded product samples 4 to 5 produced as described above are subjected to a color difference meter (trade name: CM-2600d, manufactured by Minolta Co., Ltd.), and the color difference (ΔE) from the color tone of the molded product samples 4 to 5 using white as the color difference standard. Was measured. As a result, the molded product sample 4 showed a color difference of 2.4, and the molded product sample 5 showed a color difference of 1.1. These results are shown in FIG.

<Appearance evaluation>
By observing the appearance of the molded body samples 4 to 5 produced as described above, the quality of each molded body sample was evaluated from the degree of occurrence of sink marks and flashes (good: ◯, no: x). . These results are shown in FIG.

<Evaluation of paintability>
The quality (good: ◯, no: x) of the paintability of each molded body sample was evaluated from the coating state when the molded body samples 4 to 5 produced as described above were coated. These results are shown in FIG.

<Investigation of foreign matter residue>
Using resin materials 4 to 5 , sample disks 4 to 5 (diameter 15 mm, thickness 0.5 mm) were prepared by hot pressing, and foreign matters (black color) visible by observing the appearance of the sample disks 4 to 5 The number of those having a diameter of 0.2 mm or more and one having a diameter of 0.1 mm or more and less than 0.2 mm was counted. As a result, in the sample disk 4, five foreign matters having a diameter of 0.2 mm or more were detected per disc, and 23 foreign matters having a diameter of 0.1 mm or more and less than 0.2 mm were detected per disc. The sample disk 5 detected 0 foreign matter having a diameter of 0.2 mm or more per disk and 0.5 foreign matter having a diameter of 0.1 mm or more and less than 0.2 mm per disk. These results are shown in FIG.

<Evaluation>
As shown in FIG. 5, when the physical properties of the resin material 1 and the physical properties of the resin material 4 are compared, the resin material 4 including the recycled resin (crushed material B) obtained by the conventional manufacturing method has a physical property of resin. not reach the reference desired as material, a resin material 1 comprising a recycled resin obtained by the production method according to the present invention (crushed material a) has resulted in physical properties meet all predetermined criteria. Further, compared with the physical properties of the resin material 5 made only of the virgin material, the physical properties of the resin material 1 were almost the same, and the physical properties of the resin materials 2 and 3 were both higher than the resin material 5.

FIG. 1 is a flowchart showing a process for producing a recycled resin according to an embodiment of the present invention. FIG. 2 is a diagram illustrating an example of a resin molded body that is disassembled and collected in the dismantling and collecting step. FIG. 3 is a view showing an example of a resin molded body that has undergone the removal step. FIG. 4 is a diagram showing the composition of the resin material produced in the examples and comparative examples of the present invention. FIG. 5 is a table summarizing the physical properties and evaluation results of the resin materials produced in Examples and Comparative Examples of the present invention. FIG. 6 is a flowchart of a conventional recycled resin material manufacturing method.

Claims (5)

Dismantling a product having a resin molded body and recovering the resin molded body, a removing step of removing unnecessary materials including metal parts from the resin molded body, and a classification for determining the material of the resin molded body In a method for producing a recycled resin comprising a step and a crushing step of crushing the resin molded body,
As a pre-process of the crushing process, a metal detection process for detecting the metal component, and as a subsequent process of the crushing process, the metal remaining in the crushing material obtained in the crushing process is separated and removed from the crushing material. A method for producing a recycled resin, comprising: a metal separation step. The method for producing a recycled resin according to claim 1, wherein the fractionation step further includes a flame retardance test step of measuring flame retardance of the resin molded body. The method for producing a recycled resin according to claim 1, wherein the separation step further includes a color difference measurement step of measuring a color difference of the resin molded body. The manufacturing method of the recycled resin of Claim 1 which further includes the crushing material isolation | separation process which isolate | separates the crushing material which passed through the said metal separation process using the sieve which has a mesh size of 1-5 mm. A resin material comprising a recycled resin produced by the method according to any one of claims 1 to 4 and a virgin resin.

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